In the automotive industry, manufacturers face many challenges, including long supply chains that are often affected by significant delays that jeopardize the entire production process. In a sector governed by speed and performance, these delays have serious consequences. This is where additive manufacturing comes into play, offering a reliable and repeatable production process. This is something that Automotive Entertainment, a company based in Southern California, has clearly understood, as it has integrated BigRep’s large-format technology, enabling it to design custom automotive parts and meet personalized needs, from center consoles to custom brackets and trim pieces.
3D technologies have become a real tool for the automotive industry, which has gradually moved from prototyping to finished parts. Additive manufacturing is often used because it allows for the design of custom-made components, which is particularly important for consumers looking for a unique vehicle. For example, it will make it possible to customize the interior of a car or design new features. According to a study by Straits Research, the global automotive aftermarket industry is expected to reach $70 billion by 2029, driven by the desire for customization, lighter parts and the use of new materials.
Additive manufacturing is often used to create custom-made components in cars (credits: JK Automotive Designs)
Automotive Entertainment operates in this market. It is a custom shop specializing in high-end automotive manufacturing, audio systems and all aftermarket modifications. The idea is to offer unique vehicles that meet each customer’s criteria. Speed to market and design are two key factors. They therefore needed to find a manufacturing method that would meet both requirements: how to design attractive, custom-made parts, all within short lead times and at competitive costs. Additive manufacturing quickly became the obvious choice.
BigRep’s 3D Printing Technology Offers Volume, Speed and Reliability
Automotive Entertainment turned to BigRep 3D printers because they offer a large print volume that allows them to design parts in one go, without having to assemble smaller components. This saves time and ensures durability! The team originally started with a BigRep STUDIO but updated it to BigRep VIIO 250 in 2024, satisfied with the quality and results the brand offers. This machine has a print volume of 1000 x 500 x 500 mm, two Smart Manufacturing extruders and multiple features for automated and reliable manufacturing.
JT Torres is the owner of Automotive Entertainment. He told us: “The BigRep VIIO 250 allows us to produce large-scale, high-precision parts. Our material of choice is HI-TEMP filament, which offers the strength, durability and dimensional stability required for custom automotive components. It allows us to prototype and produce everything from custom speaker enclosures to dash panels and trim pieces, all with the structural integrity required for real-world automotive use.”
The BigRep VIIO 250 has two Smart Manufacturing extruders
The Integration of Large-Format Additive Manufacturing Boosts Business Agility
Beyond the potential print volume, additive manufacturing has enabled the company to rethink its workflow and now rely on an in-house production solution. It is no longer dependent on molds manufactured by an external service provider, a process that used to take weeks. Since integrating large-scale 3D printing, Automotive Entertainment can produce its prototypes or finished parts on the same day.
JT Torres adds: “On a recent project, we saved more than two weeks on panel manufacturing alone. In terms of costs, we estimate savings of between 40 and 50%, considering labor, materials and not having to subcontract specialized work. It also minimizes rework, as we can do iterations in-house and make any necessary changes.”
The company can also rely on a smoother manufacturing process when it comes to speaker enclosures. Producing them with fiberglass molds can be messy, labor-intensive, and often leaves lingering fumes in the car. But if you use 3D scanning, you can create a digital model of the enclosure that will fit perfectly and that can be sent to the 3D printer directly. This process allows for precise, non-invasive production with greater design freedom and the possibility to iterate. This modern approach makes custom audio installations faster and more consistent.
Example of 3D printed pieces by Automotive Entertainment
It is clear how 3D printing is transforming the way parts are manufactured, customized and shipped. Supply chains are being impacted and changing; it is no longer a question of waiting for the mold, component or spare part to move forward. Companies can produce closer to the customer, on demand and faster than ever before. Additive manufacturing offers the agility needed for the automotive aftermarket to meet expectations for increased customization, sustainable production and fast delivery.
From rapid prototyping to the installation of finished parts, BigRep offers automotive innovators the tools they need to move forward quickly and efficiently. For customization workshops, equipment manufacturers and audio engineers, the message is clear: the future is printed. Find out more on the BigRep blog: in-depth analyses, customer testimonials, and technical explanations await you.
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*All Photo Credits: BigRep