3 must-see automotive 3D printing applications – powered by UltiMaker Factor 4

3D printing is transforming the automotive industry. Custom parts and tools can now be 3D printed overnight, ready to optimize production processes the next day. This innovation enhances assembly ergonomics, reduces errors, and boosts operator satisfaction and productivity.

And with the new UltiMaker Factor 4, even more is possible. Engineering-grade materials, like PPS CF can be used to 3D print obsolete parts, unlocking significant savings. Or to easily create under-the-hood components that are highly temperature resistant . From functional prototypes to flexible spare tires, 3D printing is redefining possibilities.

In this blog post, we’ll explore three cutting-edge applications of 3D printing in the automotive world. Discover how these advancements streamline workflows and revolutionize the design process. Keep reading to find out more.

High-pressure pump valve

End-use part

Overview:

• Flame retardant to UL94 V0 standard
• Resists all solvents and oil (below 200 °C)
• Replaces an obsolete part

This pump valve conducts liquids or chemicals. But because it had become an obsolete component (it was no longer produced), the entire pump assembly would need to be replaced – costing approximately €5,000. Using the latest engineering-grade composites, it can now be 3D printed, so that it still meets the required certifications for non-flammability and also for use with hot acids.

Air intake connector

End-use part

Overview:

• High thermal resistance
• Avoids long delivery times
• High cost reduction

This component is a pipe connector that channels hot air in a vehicle. It must therefore have a high temperature resistance, especially in prototype construction or as a functional component for a small series, and accordingly withstand up to 230 °C. All these requirements were met using UltiMaker PPS CF material.

Airless trolley tire

Replacement part

Overview:

• Flexible material with variable infill
• Avoids long delivery times
• High cost reduction

Instead of storing spare tires for production hall trolleys, they can simply be 3D printed. Doing so avoids the need for spare part warehousing. This example is a scaled-down version of a real customer component. It shows what’s possible by 3D printing UltiMaker TPU 95A on the UltiMaker Factor 4. Infill pattern and density can be easily adjusted to emulate the traditional tire pressure. A more flexible TPU 70A – offered by a third-party material partner – can also be used.

Take the next step

Learn more about how leading automotive companies are using 3D printing to streamline production workflows. This in-depth guide walks you through the benefits - including reducing the pressure on your design process - and how to make the most of in-house 3D printing.

Download the free guide

Want more inspiration? Check out how Audi Sport has professionalized 3D printing in their high-end automotive production process.

Watch the success story