The automotive industry has always depended on rigorous design, validation, prototyping and manufacturing processes. However, with the evolution of Industry 4.0, additive manufacturing has come to play an increasingly important role in reducing lead times, costs and technical complexity.
In this context, SLA technology — industrial stereolithography — stands out as an effective solution for the rapid development of automotive models, functional prototypes, moulds and validation components. Kings 3D presents an application case in which SLA 3D printing is used at different stages of the automotive process, from initial design through to after-sales maintenance.
From Concept to Physical Model in Less Time
Traditionally, after the concept and design phase, automotive manufacturers produce scale models, usually at 1:5 scale, to assess different proposals. Once the best options have been selected, the process moves on to full-size 1:1 models, which are subjected to aesthetic analysis, aerodynamic testing and successive design changes.
Using traditional methods, a complete clay model can take around three months to be produced manually. Even with 5-axis CNC milling, manufacturing an automotive model can require at least one month. Large-format SLA 3D printing makes it possible to significantly shorten this process, enabling 1:1 models to be produced in just a few days from digital data. According to Kings 3D, this approach can reduce process time by at least five times and lower costs by around half.
Greater Flexibility in the Engineering Phase
In the engineering phase, each new vehicle involves the coordination of thousands of components. Kings 3D states that a new car can include more than 20,000 parts, many of which are not yet in mould production during the early stages of development.
At these stages, test parts and assembly products are often produced using CNC machining or sheet metal. However, complex geometries, curved surfaces and components with multiple machining areas can make the process more expensive, time-consuming or technically limited.
The solution presented combines high-precision SLA 3D printing with vacuum casting. The process begins with the 3D printing of the prototype, followed by the production of a silicone mould under vacuum, and ends with the casting of materials such as PU in a low-pressure environment. The result is parts with performance comparable to injection-moulded components, capable of replacing applications in ABS, PC, rubber and other technical materials.
Application in Complex Components
Elements such as front grilles, curved structures, interior and exterior components, or design details with high geometric complexity can be difficult to produce using conventional methods. 3D printing makes it possible to manufacture these areas quickly and accurately, later integrating them into the vehicle model for aesthetic, dimensional or functional validation.
This capability is particularly relevant for design, engineering and prototyping teams that need to test several iterations within a short period of time, while maintaining surface quality, geometric detail and dimensional control.
Prototyping and Testing Before Production
During the prototype testing phase, manufacturers evaluate performance, reliability, strength and durability. Tests such as wind tunnel testing, road testing, field testing and crash testing are part of the automotive validation process.
For parts that require high structural strength, CNC machining continues to have its place. However, for many interior and exterior components, the combination of SLA 3D printing and vacuum casting offers a fast and cost-effective alternative for validation before final production.
Moulds and Industrial Production
SLA technology can also support the production of prototypes for casting moulds. In the case of automotive components such as panels, covers or engine blocks, precision requirements can reach values in the range of 10 to 20 microns. Kings 3D highlights the use of the large-format Kings1700 SLA printer, equipped with a multi-laser system, for the production of prototypes intended for sand moulds, simplifying processes and reducing costs in foundry operations.
Solutions Also for Maintenance and Replacement Parts
SLA 3D printing can also be applied in after-sales maintenance, especially for customised, sports, modified or low-production vehicles. In these cases, ordering small quantities of replacement parts from the original manufacturer or producing dedicated moulds can be costly. 3D printing enables specific components to be obtained in a more economical and flexible way.
NM3D Ibérica: Additive Technology at the Service of Industry
At NM3D Ibérica, we support industrial companies in the assessment and implementation of additive manufacturing, rapid prototyping, dimensional control and reverse engineering solutions, helping to accelerate product development and reduce costs in validation processes.
Industrial 3D printing is not merely a prototyping tool. It is a strategic technology for companies seeking greater agility, greater design freedom and a faster response to the demands of the automotive market.