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Case Studies:

Automotive

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Solaxis: Easy Assembly with Additive Manufactruing

With the help of Fortus 3D Printers, Solaxis designed and manufactured a jig for an automotive supplier, which uses it to assemble high-volume plastic door seals. After developing several iterations of the jig, Solaxis was not only able to produce a 3D printed jig that is over 100 pounds lighter than a typical jig for this application, but it also slashed the design and manufacturing time by at least two thirds compared with traditional methods.

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Magna Closures: 3D Digital Technologies Drive Productivity

“The reduction in the time and cost of proposing new designs has enabled us to increase the number of product development projects by a factor of five without increasing our staff. We can also respond more quickly to customer requests, which increases the odds of getting the order. As many of our higher volume of proposals come to fruition, we expect to see a substantial increase in revenues.”

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Volvo Trucking uses Addive Manufacturing to Create Long-Haul Tooling

“The capability to produce a virtually unlimited range of functional tools in such a short timeframe is unprecedented and enables us to be more experimental and inventive to improve production workflow.”

- Pierre Jenny, Manufacturing Director, Volvo Trucks

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Formula for Success: 3D Printing Helps Students Build Formula SAE Racecar

“With our 3D printers, we can design and make prototype parts quickly and efficiently. Printing a part now takes about three days. Previously it took two to three weeks to get a final result. What’s more we save thousands of dollars in development costs. This automatically makes us more competitive because cost is a key element in the competition.”

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Alesca: Lightening the Load with Fortus Technology

“The 3D printer from Stratasys lets us shrink the time to create tooling from three or four weeks to three or four days. We don’t have to order aluminum or steel and mill it.” Additive manufacturing lets the development team try more design options, shorten development times and show customers a part that’s production ready.

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Hanil Slashes R&D Time and Enhances Prototyping with Stratasys Technilogies

“FDM has advantages that include part strength and ease of modification. These are important traits when assembling prototypes for confirmation of quality and suitability of design.”

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Joe Gibs Racing Wins with Custom Gauges

Adapting to the specific challenges of each race means NASCAR teams often modify their cars every week. The cars typically return from a race on Monday and are shipped out again Thursday, leaving engineers only three days to get feedback from drivers, then build, test and install new parts on the car. This process rarely gets done to the teams’ satisfaction when using traditional manufacturing, which is why engineers from Joe Gibbs Racing (JGR) use 3D printing.

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Harman Becker: High-Spec Design Engineering, Streamlined

The Harman Becker design team sought a quick, effective and, above all, high- quality solution for developing functional 3D models. They demanded ease of use, replication that captured the quality of their designs and, most importantly, a robust output material that would not fracture, distort or require too much refining and cleaning up prior to fitting.

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Kingston University E-Racing Conquers Challenges with Additive Manufacturing

“Using additive manufacturing, we were able to overcome our main developmental concern to manufacture parts that could withstand the gruelling pace and heat of motor-racing. With the toughness of our 3D printed parts, the results did not disappoint, particularly the shutdown button mounting which needed to withstand sudden shock when slamming the button hard during an emergency.”

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Triple Eight Racing: Accelerating the Design Process with FDM Technology

“The Dimension Elite 3D Printer has reduced our time to market by speeding up our design process and increasing our prototyping precision,” says Craig Johnstone, machine shop manager of Triple Eight. “The level of flexibility in producing custom parts for testing is remarkable and we can get real-time, real- life feedback on different designs, eliminating any theoretical guesswork based on what-ifs.”

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RENNtech Designs Winning Race Car in Just 35 Days with Stratasys Technologies

“Producing strong, yet lightweight, parts in ABS plastic was a big factor for me in the decision to purchase the Dimension 3D Printer. We wouldn’t have completed the project with any other technology.”

- Dustin Hanna, RENNtech

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Konigsegg Speeding Ahead with Additive Manufacturing

“Dimension was an obvious choice for us as it not only allows us to modify and print prototypes quickly but also provides us with the option to use them as end use parts in our cars. Once the Dimension 3D Printer was up and running, our engineers started using the machine straight away. The benefits were clear immediately. The process of printing prototypes onsite and testing each component has sped up the development of the car design by an estimated 20%.”

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Hyundia Motors: FDM Dashboard Prototype Fit to Drive

Before installing the instrument panel model in a cockpit assembly, the design team mounted it on a fixture and scrutinized it with a coordinate measuring machine, and captured hundreds of measurements. According to Tae Sun Byun, principal research engineer for the Hyundai Mobis Auto-Tech division, “Dimensional accuracy and dimensional stability were critical for the design verification. The FDM system, with its ABS plastic, gave us both. Over a length of 1382 mm, the greatest deviation was just 0.75 mm.”

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JGR Trims Tims with FDM Cutting Fixtures

“We didn’t even give CNC machining a second thought. It was obvious that FDM was our best option. Just one look at the fixture and we knew that it would be too much work and take too much time to get it milled on one of our CNCs.”

- Mark Bringle, Technical Manager, Joe Gibbs Racing

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Ducati Races Forward with Engine Design With In-house Fortus 3D Printing Systems

Speed, durability and functionality are critical in motorcycle engines and the engineers at Ducati found all of this by using its two Fortus machines to create a winning engine in just eight months, versus 28 months when prototype needs were outsourced to a service bureau.

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MVCD Racing Reduces Prototyping Time By 75%

MCD's ability to quickly generate additional design iterations often helps the company improve the design resulting in better performance on the track. MCD reqired parts strong enough for functional testing. Pretty parts did not cut it. Their Dimension 3D printer helped them identify and fix mnay potential problems. The savings more than justified their purchase.

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Polaris Praises Fortus for Reducing Tooling Costs by $60,000 per Part and Speeding Time-to-Market.

On average, tooled snowmobile parts previously took eight to 12 weeks, at about $60,000 each. Now, Polaris in-house FDM machine cuts the time to about two days with outstanding cost savings as a bonus. With PC-ABS materials, functional prototypes are tested and refined long before they hit the snow.

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Joe Gibbs Racing Speeds Ahead With Fortus, Taking Design to Concept Car within Days

Fortus prototypes -- ready in days, not weeks - help race team engineers speed ahead with design concepts that beat out the competition. Not only are prototypes built quickly; they are tough enough to go from concept to car - even the engine block - for quick evaluation.

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BMW Produces Jigs and Fixtures in Hours and Reduces Part Weight by 72% With Stratasys 3D Printing

BMW speeds production by creating fabrication and assembly tools via direct digital manufacturing. No outsourced machining means the tools are produced in hours, not weeks. With an average automaker using over 400 assembly tools per vehicle, the money and time-savings potential is enormous.

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Urbee, The First Prototype Car to Have Entire Body 3D Printed

Urbee is the first prototype car ever to have its entire body 3D printed with an additive process. All exterior components - including the glass panel prototypes - were created using Dimension 3D Printers and Fortus 3D Production Systems. FDM technology made it easy and efficient to make design changes in the Urbee along the way. It also helped them meet their environmental goals by eliminating tooling, machining and handwork.

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Watch CNN Interview

DDM Components Help Win Discovery Channel's Biker Build-Off

“Direct digital manufacturing gave us a major edge in the competition,” says Jesse Hanssen, Klock Werks mechanical engineer. “The [Fortus] FDM system enabled us to build anything we could imagine.”

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British Automotive Design & Manufacturing Firm Reduces Prototyping Times By 68%

Prototyping and manufacturing using the Stratasys machine plays a significant part in helping to reduce development costs across the board. The Fortus 400mc has been involved throughout the design and prototype of the company's inaugural vehicle, codenamed T.25. The T.25 represents a major breakthrough in city car design.

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