GM Uses Additive Manufacturing for Better Car Manufacturing

Ferrari, BMW, Rolls-Royce, Lamborghini, Audi, Volvo…nowadays, it seems that all the major car manufacturers are using 3D printing. This includes in the United States, where companies like Ford have hardly made a secret of their appreciation for 3D technologies for even end-use parts. Now another major American brand, GM, is showing its appreciation for additive manufacturing.

GM, or General Motors, is an American multinational automotive manufacturing company that is not only the largest automaker in the US, but was also the largest in the world until 2008. Famous for its Chevrolet, Buick, GMC and Cadillac brands, the manufacturer has had to be at the forefront of innovation as it pushes to be the best. Including by adopting additive manufacturing.

Lansing Delta Township team member Kayla Dubois uses a 3D printed hood fixture

Actually, we had known that GM has been using 3D printing for some time. The brand used it in its Cadillac CELESTIQ, which integrated 115 metal and polymer 3D printed components. It has also used to everything from seals to tooling and more. In fact, the company installed its first 3D printer, a stereolithography solution, all the way back in 1989! Now, GM has confirmed the importance of additive manufacturing for the company in its plants to make different cars.

GM Turns to Additive Manufacturing

In a recent press release, GM noted that it is always looking to create “more efficient processes, cost-effective designs and safer practices.” One of the ways that it is doing this is with additive manufacturing, for everything from pre-production to motorsports. The company further notes that 3D printing has been integral in applications like design, product and materials engineering, vehicle manufacturing, and after sales for products in body hardware and electrical, interior and more.

More specifically, GM notes that the current ways it is using additive manufacturing is for early part prototypes to supplement virtual designs, simplification of tools and fixtures, operator assists in manufacturing plants and cost-effective and durable production components. One of the more interesting ways in which it is being implemented is to improve in-plant processes for those working on the assembly line. One such example from the company comes from team members at Lansing Delta Township Assembly, where the Buick Enclave, Chevrolet Traverse and GMC Acadia are made.

GM AM technical specialist Paul Wolcott removes a finished part from a 3D printer at the Warren Technical Center campus

Here, the team members are using additive manufacturing to make vehicle assembly easier. As such, they looked to improve a metal fixture that is used to prop open vehicle hoods before attaching them to their hinges. The problem? The fixtures were made of titanium and steel, meaning each one weighs in at about 14 pounds. This is more than the 10-pound limit for a one-hand lift. 3D printing provided the solution.

Not only did additive manufacturing enable the GM workers to develop a new and lighter design for the part, but it could even be made with additive manufacturing, also helping to decrease the weight. “Additive manufacturing continues to enable us to build our vehicles safer and quicker,” explains Paul Wolcott, a GM technical specialist. “From accelerated lead times for tools to addressing ergonomic issues with lightweight solutions, we keep seeing growth in applications the more we implement it.”

In any case, it seems that in 2024 GM had over 5,400 new additive manufacturing projects. A number that is expected to grow in 2025 with even more applications. A sure sign of additive manufacturing’s place in the automotive sector.

What do you think of how GM is using additive manufacturing? What applications using 3D printing would you like to see from the automaker? Let us know in a comment below or on our LinkedIn, Facebook, and Twitter pages! Don’t forget to sign up for our free weekly Newsletter here, the latest 3D printing news straight to your inbox! You can also find all our videos on our YouTube channel.

*All Photo Credits: GM