3D printingin the automotive sector

Additive manufacturing in practice

What still sounds like the future to many has long since become standard practice for others: More and more companies are producing spare parts and specialised components using 3D printers. Under the term “additive manufacturing,” these new processes are now also making their way into industrial production. One of the greatest advantages of 3D printing is the ability to tailor components to individual requirements. At thyssenkrupp Springs & Stabilizers, 3D-printed parts are also used to supply various specialist departments.

How 3D printing is transforming production

In additive manufacturing, the focus is on the development and production of components that either cannot be produced with conventional methods or for which the manufacturing process is to be simplified. The key advantage of 3D printing lies in time savings compared to production using traditional manufacturing methods. Products that used to take a significant amount of time to manufacture can now be produced within a few hours. Thanks to additive manufacturing, internal and external customers can now be supplied with 3D-printed parts, component waiting times can be reduced, and departmental efficiency can be increased.

Advantages of 3D-printed components

Furthermore, the 3D-printed spare parts often exhibit significantly better durability than the original parts. This is partly due to the choice of materials. As a result, automotive customers were convinced to transfer orders to thefacility in Hagen. A prime example is the production of spring caps for the Fisker Ocean (2022) and the Jaguar Landrover (2023). These 'spring caps enable the installation of many new automotive springs and are often made of rubber. With the 3D printing of rubber spring caps, the waiting time for such parts can be significantly reduced compared to the traditional injection molding process for spring caps. Additionally, they provide better damping than metal and plastic variants and are often more cost-effective in production.

Uncomplicated spare part manufacturing – 3D printing in action

When looking at the production and quality assurance of components at thyssenkrupp Springs & Stabilizers, 3D printing saves a significant amount of time and costs. External tool suppliers incur enormous costs, and sometimes a simple plastic part is sufficient, for example, to perform a spring cap test. Additionally, custom-made or low-volume components are often expensive. To produce them, a tool may need to be specially made, which in turn involves time and effort. During the design and development phase, a spring seat is modified repeatedly. Numerous correction loops are required before the final component fits perfectly. With conventional production methods, this process would take months. Additive manufacturing can reduce it to just a few days.

From a single printer to series production

It all began in the year 2018. Now, there are eight printers. The list of 3D-printed components has grown to encompass more than 1,200 projects. It can be assumed that, in the future, an increasing number of parts used in series-production vehicles will be 3D-printed, as declining private vehicle use and the resulting lower production volumes may make more complex manufacturing processes economically unviable. Currently, the projects can still be categorized into four main areas: the production of spare parts for production, manufacturing, and testing machines; test setups for the testing and quality assurance area; the manufacturing of prototypes; and finally, the production of spring caps for direct installation in vehicles.

Limitless possibilities

The potential of 3D printing is enormous. Thanks to additive manufacturing, thyssenkrupp Springs & Stabilizers has been able to completely rethink its production and processes. Low production costs shortened delivery times, and a short response time between the issuance of a printing order and the completion of the print could be crucial for the manufacturing of components in the automotive sector in the future. However, not only time savings play an important role but also the creation of spare parts for older machines or vehicles, the production of complex components, or even when original spare parts are no longer available.

The increased availability through mass production is another crucial aspect favoring 3D printing. This allows for a significant boost in the availability of spare parts since the needed components can be manufactured on demand an the need for stocking spare parts would no longer be necessary in this scenario.

Between time pressure and complexity

Nevertheless, there is still room for improvement when it comes to 3D printing. The biggest challenges are the high workload, time pressure and the complexity of the components. Every component is different, and a program has to be created to ensure optimal printing and the durability of the part.

The future of 3D printing in toolmaking and the automotive industry

Toolmaking at thyssenkrupp is also being continuously developed and expanded in order to keep pace with growing demand and the wide range of possible applications. The insights from the tool design can later also be applied to other industrial processes. One particularly interesting prospect for the future is the possibility of not only supplying customers with finished 3D-printed products, but also acting as a service provider for other customers.