Toyota Integrates 3D Printing In Its New Concept SUV

Looks like summer just won’t go away! Toyota surprised attendees at the 2024 SEMA Show in Las Vegas with the unveiling of the 4Runner TRD Surf Concept. The concept vehicle integrates additive manufacturing and a design inspired by California surf culture. The brand is no stranger to the use of additive manufacturing. This year, Toyota’s Customizing & Development department had already launched the Hyper-F SUV concept, a vehicle that featured multiple 3D printed parts, showing the potential of the technology in the automotive sector.

The new 4Runner TRD Surf concept is an ode to classic SUVs that, in their first generations, already possess the essence of adventure and freedom that defines the 4Runner model. This new concept revives the nostalgia of removable roofs, a nod to the surfing lifestyle of Southern California. Now, with the 4Runner TRD Surf Concept, Toyota goes a step further by including a 3D printed removable roof, which combines lightness, precision and a design perfectly adapted to the vehicle.

Toyota unveiled the 4Runner TRD Surf Concept SUV at the SEMA Show in Las Vegas.

The 3D Roof of the 4Runner TRD Surf Concept

Additive manufacturing has allowed Toyota designers more freedom and flexibility to create complex parts without the limitations of traditional manufacturing methods. This roof, designed in the Toyota Motorsport Garage and made from advanced materials, is the result of a blend of traditional and modern techniques, including the advanced use of CAD and 3D printing. In this way, the manufacturer ensures that the roof is visually appealing, as well as functional, lightweight and easy for one person to remove.

For Toyota’s design team, the challenge was not only to innovate in terms of aesthetics but also in terms of functionality and practicality. One technical challenge the team faced was redesigning the SUV from a four-door to a two-door. They also had to ensure that the vehicle would function perfectly both with and without the roof in place.

The use of additive manufacturing made it possible to create the roof cut lines with millimeter precision, ensuring a perfect fit on the body. Marty Schwerter, chief builder and director of operations at the Toyota Motorsport Technical Center explains that his goal was not just to make aesthetic or mechanical changes to the vehicle, but to get all of these elements to work in perfect harmony. “What makes this build so stellar has less to do with the changes themselves and more to do with the amazing way that they all work together—the result is truly greater than the sum of the parts,” Schwerter said.

The 3D printed roof of the 4Runner TRD Surf SUV can be deployed by a single person

With a 2.4L iForce turbocharged 2.4L engine offering 278 horsepower and an eight-speed automatic transmission, the TRD Surf Concept doesn’t fall short on performance. Its all-wheel-drive system and an electronically controlled dual-range transfer case ensure a responsive driving experience on both sandy terrain and conventional roads. In addition, it features a custom exhaust that provides a distinctive exhaust note designed to resonate with the 4Runner’s “Go-Anywhere” spirit. For more details on this concept SUV, check out Toyota’s press release here.

What do you think of Toyota’s new SUV? 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: Toyota