Major automakers are scaling up their adoption of 3D printing technology, also known as additive manufacturing, to streamline production and lower expenses. The process creates three-dimensional objects from digital designs by layering materials such as plastics, composites, ceramics, and metals. While the technology has existed for decades, it is now becoming more widely utilized throughout vehicle manufacturing operations.
Rivian has invested more than $5 million in 3D-printing equipment, with annual material costs reaching approximately $1.7 million. According to Jonathan Dankenbring, the automaker’s senior manager of prototype manufacturing, the machines typically pay for themselves within a year by reducing supplier tooling costs, lowering logistics expenses, and cutting production timelines from weeks to days or hours. Rivian is expanding its capabilities to include machines for flexible silicone parts and has installed equipment at its Normal, Illinois facility to enable employees to manufacture parts on demand.
Ford has deployed additive manufacturing departments across numerous plants, including a vending machine for 3D-printed parts at its Dearborn headquarters facility. The automaker’s program currently operates more than 200 machines, with plans to expand 3D labs to more than 23 plants by year-end. Employees can request custom tools and parts through an app, allowing faster turnaround and lower costs compared to traditional manufacturing methods. Ford has also used 3D-printed components to maintain production continuity when permanent replacements were unavailable.
General Motors has integrated 3D-printed parts into production vehicles, with 135 components used in the Cadillac Celestiq and additional components for the Cadillac Blackwing sedan. Fadi Abro, senior global director of automotive and mobility at 3D-printing company Stratasys, noted that improvements in material properties have expanded potential applications. Industry experts emphasize the need for continued technological advancement to make 3D printing faster and more economically accessible across the automotive sector.
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