How Is 3D Printing Being Used for Electric Cars?

With the increasing availability of hybrid and electric vehicles, the automotive industry is increasingly turning towards sustainability and away from fossil fuels. As the sector is known for its constant innovation, electric cars and recent projects showcase advances in manufacturing, performance and design. So it’s natural to see that many electric vehicles incorporate 3D-printed parts and are designed using 3D modeling software. Here is a list illustrating the use of 3D printing in electric cars, offering an overview of its current role. The examples are presented in no particular order and reflect the current state of 3D printing in this field.

3D Printing in the Ford Electric Explorer SUV

A recent project implementing 3D printing in the manufacture of electric vehicles is Ford’s Explorer SUV. The American automaker used SLA and SLS 3D printing technologies for this model. Ford uses Formlabs’ solutions to create prototypes of various components such as mirrors, door handles, dashboard parts, as well as mechanical elements and assemblies. The company has long combined traditional production methods with 3D printing to improve material utilization, reduce costs, and increase production efficiency and speed.

3D-printed parts for Ford’s Explorer SUV (photo credits: Ford)

The e-Miles L7e

The e-Miles Company is dedicated to developing greener mobility solutions. It recently launched the e-Miles L7e, an electric car specially designed for urban environments and sustainable freight transport. This vehicle stands out for its unique driving system, using a button instead of a steering wheel and pedals, making it accessible to a wide audience. The quadricycle is made up of 90% 3D-printed parts, from bodywork to interior components. Equipped with batteries that can be recharged in 8 hours, and an 8 kW motor, the e-Miles L7e can reach a top speed of 85 km/h.

Photo Credits: The e-Miles Company

Drexel Electric Racing Turns to Metal 3D Printing for its Race Vehicles

When you think of racecars, you probably don’t picture electric vehicles. But electric racecars are a very real thing, as is clear from Drexel Electric Racing! This student-led team creates open-wheel electric racecars to compete in FSAE events. And they are turning to 3D printing to create these electric vehicles! Recently, the racing team took part in the SolidCAM Additive Challenge which gave them access to the latest 3D printing technologies in order to help optimize production processes. Clearly, they were convinced as they integrated metal additive manufacturing in their single-seater race car, more specifically turning to metal binder jetting and Bound Metal Deposition™. In the end, the students were able to create two steel back spindles and steel battery holders as well as steering wheel grips made with resin 3D printing. A clear sign of the usefulness of 3D printing technologies in electric vehicle racing!

Photo Credits: SolidCAM

UILA, the 3D Printed Cargo Bike Electric Vehicle for Urban Travel

This next inclusion is especially notable because it amazed attendees at Formnext 2022 with its ingenuity and design. What are we talking about? Why the UILA from nFrontier of course! This combination cargo bike electric vehicle has been designed specifically for sustainable mobility, creating a new category ideal for combating climate change and the energy crisis. The four-wheeled, two-seater was made using Stratasys’s FDM technology for the large format body components while powder-based SAF solutions and P3 systems were used for higher-volume additive manufacturing for the vehicle. And the best part? Since it is pedal operated, no driver’s license is needed! Making it the perfect solution for urban travel.

Photo Credits: nFrontier

The MINI Electric Pacesetter

On April 10, 2021, the JCW-inspired MINI Electric Pacesetter completed its first lap as a safety car in a Formula E race. The car, derived from the MINI Cooper, was designed by JCS in collaboration with BMW, MINI Design, the FIA and Formula E. As a Safety Car, its role is to guide the peloton in the event of an accident or danger, and to slow down the race. The MINI Electric Pacesetter incorporates numerous innovations, such as customizable 3D-printed seats, a printed fairing to improve aerodynamics, and rear spoilers also made using 3D printing.

Photo Credits: BMW Group

Solar-Powered Electric Cars From Aptera

Aptera’s mission is to create the most efficient electric vehicle, powered primarily by solar energy. This approach aims to eliminate dependence on other sources of electricity and enable users to reduce their carbon footprint by more than 6,000 kilos a year, according to Aptera. The futuristic design of Aptera’s vehicles, inspired by racing cars and fighter jets, is designed to optimize fuel efficiency through improved aerodynamics. As a result, these vehicles are expected to consume around 30% less energy than other electric and hybrid vehicles. To make this design a reality, Aptera is using artificial intelligence and 3D printing of composite materials, although the details of the process are still unknown. The company plans to start production by the end of 2024, subject to meeting its funding targets by then. Aptera models are expected to be priced between $25,900 and $46,000.

Photo Credits: Alpha Sol, Aptera

The YoYo from XEV

The YoYo, a model designed by the Italian company XEV, stands out for its use of 3D printing in its manufacture. This 100% electric vehicle, equipped with three interchangeable batteries, offers a high degree of customization thanks to this technology. Some parts, such as the “blade” (the side spoiler) and interior elements, can be adapted to users’ preferences. Available in four versions, the YoYo offers options ranging from the more affordable basic model to a top-of-the-range version with larger wheels, a bigger screen and power steering. Maximum speed is 80 km/h.

Arash Motor Company’s Hypercar

Arash Motor Company, which specializes in the manufacture of bespoke supercars, relies on 3D printing to produce parts for its latest next-generation hypercar. Led by founder and lead designer Arash Farboud, the company has designed this model for peak performance, with a carbon engine, multiple electric motors and an optimized aerodynamic design. For the latter project, the team employed three MakerBot 3D printers, including the Replicator Z18, to create complex parts such as the suspension and aerodynamic elements. The METHOD X was also important for the production of carbon fiber-reinforced nylon parts, reducing weight while maintaining the necessary robustness. This approach was particularly useful for components such as the rear wing and chassis, where lightness was essential.

Photo Creidts: UltiMaker

Bugatti’s Tourbillon Hypercar

The Tourbillon hypercar from Bugatti, the prestigious Italian brand, boasts a 3D-printed chassis and suspension thanks to the Divergent Adaptive Production System, an innovative technology developed by Divergent, an American company. This method makes it possible to create lighter, higher-performance components, with a notable 45% reduction in suspension weight. Indeed, the Tourbillon chassis features a 3D-printed aluminum multi-link suspension. What’s more, many of the structural reinforcements were designed in 3D using cutting-edge materials such as carbon composites. This material was used for the overall structure of the vehicle, as well as for the front air ducts and rear diffuser, helping to improve the car’s performance and lightness.

Photo Credits: Bugatti

The Fiat Topolino Electric Vehicle

This project, which resulted in the creation of a customized Fiat Topolino using 3D printing, was not carried out directly by FIAT, but by the Italian company Carrozzeria Castagna. The company completely redesigned the electric Beetle using 3D printing. The various body parts are made from carbon fiber using an exclusive process developed by Castagna. The car offers a high degree of personalization, allowing a choice from a wide range of finishes and colors, from pastel hues to metallics, as well as wood details.

Photo Credits: Castagna Milano

LIUX and Animal

At the end of 2022, Santa Pola, Spain-based LIUX unveiled its Animal concept car. This all-electric, 3D-printed vehicle aims to revolutionize mobility and sustainability. Made from organic materials, it features a modular battery and an elegant design. The interior, exterior and part of the chassis are made from biopolymers composed of organic fibers and resin, while other materials such as cork and linseed are also used. Thanks to additive manufacturing, LIUX has not only reduced production times and energy consumption by 70%, but has also lightened the bodywork, making this electric vehicle more environmentally friendly.

3D Printing in the Renault 5 E-tech Electric Vehicle

This year, Renault has reintroduced its iconic Renault 5 in a new, all-electric form, christened the Renault 5 E-Tech. This urban model, with a range of 400 kilometers, stands out for its compact design and customization options. Innovations include the integration of 3D-printed accessories in the cabin, such as storage spaces in a variety of colors and patterns. This adds both functionality and originality to the driving experience. Renault also emphasizes the model’s sustainability, announcing 85% recyclability, with 19.4% recycled materials and 26.6% from the circular economy. Available in five colors, the Renault 5 E-Tech marks a step forward in the brand’s sustainable mobility strategy.

Photo Credits: Renault

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