3D printing electric vehicles advantages and uses

The electric vehicle market and 3D printing are experiencing rapid growth.

In this regard, private mobility is witnessing the production of an ever-increasing number of PHEV (Plug-in Hybrid Electric Vehicle) or BEV (Battery Electric Vehicle) vehicles in circulation.

A recent study by the Milan Polytechnic predicts that within the current decade one in seven cars will be electric.

3D printing in the production of electric vehicles

From an industrial point of view, this evolution has already triggered the development and innovation of products designed to respond to the growing needs of the market.

When we talk about electric vehicles we are referring to cars, but also to other sports and electronic products designed and developed to work with the use of electric current.

All phases of 3D printing in electric vehicles

The increase in demand for electric vehicles leads to ever tighter and tighter product development times.

To achieve this result it is necessary to design products suitable for latest generation 3D printing technologies designed to simplify all production steps as much as possible.

This scenario paves the way for rapid prototyping: the design files, in fact, can be easily modified before being instantly printed and testing a physical version of the piece.

Goals with 3D printing production

The performance of electric vehicles has been well known for some time.

Just think of the results of the oldest hill climb in the history of American motoring Pikes Peak International Hill Climb.

In 2018 Romain Dumas aboard the first fully electric racing car produced by Volkswagen, the I.D.R. Pikes Peak set a new trail time record.

3D printing and additive printing technologies have contributed significantly to achieving this record.

But what are the advantages of using additive prototyping processes in electric vehicles?

1. Production speed with 3D printing

Many tests, including functional ones, can be performed with parts produced with 3D printing. This allows us to accelerate the development phases and carry out tests even in the wind tunnel.

Added to this is that all design files can be quickly edited and tested to streamline the entire engineering process.

2. Optimization and weight reduction

The use of 3D printing allows you to produce lighter components, without sacrificing the quality of the components.

With adequate design, the resistance and safety of the components improves, consequently improving the efficiency and autonomy of the battery.

3. Production without equipment

3D printing eliminates the foundation of traditional manufacturing technologies: the tool building. From the 3D file the transition to prototyping is immediate, reducing production times and waste.

4. High performance materials

To date, new technologies and new materials really allow the use of 3D printed components as if they were production.

Thanks to flexible, rigid and transparent materials, resistant to high temperatures, exposure to UV rays and chemical substances > and much more

All typical conditions of the life cycle of an electric vehicle.

5. Low volume production

Product development, in all industrial sectors, has a common thread that unites them all: customization.

More and more often, customer requests are for unique and recognizable pieces. The manufacturing market responds with custom solutions that help optimize the customer experience.

From this perspective, 3D printing is widely used, facilitating the possibility of having customized pieces as much as possible.

6. Production autonomy

3D printing technologies make the manufacturing industry very independent.

To meet rapid production times, many companies have equipped themselves with prototyping systems or have to refer to the domestic market for purchases.

Technologies

Until a few years ago, rapid prototyping technologies were only used in the prototype field.

Today many 3D printed pieces are used as definitive.

The technologies most used for this use are FDM, MJF and DLP.

Study cases

This product is an electric vehicle charging system.

3D printing was used to validate all engineering and product development phases with excellent results in terms of reducing product development times and costs.