{"id":59849,"date":"2024-09-20T12:00:21","date_gmt":"2024-09-20T10:00:21","guid":{"rendered":"https:\/\/www.3dnatives.com\/en\/?p=59849"},"modified":"2024-09-20T15:38:54","modified_gmt":"2024-09-20T13:38:54","slug":"how-is-3d-printing-being-used-for-electric-cars-200920244","status":"publish","type":"post","link":"https:\/\/www.3dnatives.com\/en\/how-is-3d-printing-being-used-for-electric-cars-200920244\/","title":{"rendered":"How Is 3D Printing Being Used for Electric Cars?"},"content":{"rendered":"

With the increasing availability of hybrid and electric vehicles, the automotive<\/a> 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<\/a>. 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.<\/p>\n

3D Printing in the Ford Electric Explorer SUV<\/h3>\n

A recent project implementing 3D printing in the manufacture of electric vehicles is Ford’s Explorer SUV<\/a>. The American automaker used SLA<\/a> and SLS<\/a> 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.<\/p>\n

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3D-printed parts for Ford’s Explorer SUV (photo credits: Ford)<\/p><\/div>\n

The e-Miles L7e<\/h3>\n

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.<\/p>

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Photo Credits: The e-Miles Company<\/p><\/div>\n

Drexel Electric Racing Turns to Metal 3D Printing for its Race Vehicles<\/h3>\n

When you think of racecars, you probably don\u2019t picture electric vehicles. But electric racecars are a very real thing, as is clear from Drexel Electric Racing<\/a>! 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\u2122. 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!<\/p>\n

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Photo Credits: SolidCAM<\/p><\/div>\n

UILA, the 3D Printed Cargo Bike Electric Vehicle for Urban Travel<\/h3>\n

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<\/a> 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\u2019s 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\u2019s license is needed! Making it the perfect solution for urban travel.<\/p>\n

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Photo Credits: nFrontier<\/p><\/div>\n

The MINI Electric Pacesetter<\/h3>\n

On April 10, 2021, the JCW-inspired MINI Electric Pacesetter<\/a> 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.<\/p>\n

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Photo Credits: BMW Group<\/p><\/div>\n

Solar-Powered Electric Cars From Aptera<\/h3>\n

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.<\/p>\n

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Photo Credits: Alpha Sol, Aptera<\/p><\/div>\n

The YoYo from XEV<\/h3>\n

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 \u201cblade\u201d (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.<\/p>\n