In the world of autonomous vehicle development, speed and adaptability are key. Traditional manufacturing methods often struggle to keep up with the rapid iteration required to test and refine these cutting-edge technologies. That’s where 3D printing comes in.
At Lunia 3D, we had the opportunity to take on an ambitious challenge: producing a full-scale prototype shell for an autonomous vehicle within a tight three-month deadline. This project pushed the limits of 3D printing technology and showcased the incredible potential of additive manufacturing in the automotive sector.
The Project Scope
Our task was to 3D print a full-scale autonomous vehicle shell, composed of 120 individual parts. Each component had to be precisely printed and engineered for seamless assembly. Notably, this project was completed before we acquired our large-format BigRep One 3D printer, meaning we had to rely on smaller printers and strategic part segmentation to bring the design to life.
The purpose of the 3D printed prototype was to facilitate testing and data gathering for self-driving vehicle technology. By using a rapid production method like 3D printing, the company we collaborated with was able to meet their tight deadline—a timeline that would have been nearly impossible using traditional manufacturing techniques.
The Process
To bring the vehicle to life, we meticulously planned the printing process, ensuring efficiency and precision in every step. We started by segmenting the CAD model into 120 individual parts that could be printed using our available 3D printers. These segments were strategically designed with interlocking features and alignment markers to facilitate seamless assembly.
We used 99.5% recycled material from Filamentive, reinforcing our commitment to sustainable manufacturing. Each part was printed with high precision, ensuring dimensional accuracy and durability. The printing process required careful monitoring to maintain consistency across all components. Given the number of parts, the entire production required a well-coordinated workflow to optimize print times and avoid bottlenecks.
Once printed, the components underwent post-processing, which included sanding and surface finishing ensuring a smooth fit during assembly. The individual pieces were then shipped to a partner company, where they were meticulously assembled into a full vehicle shell. To enhance strength and improve the final aesthetic, the assembled structure was coated with a fibreglass wrap, adding durability and a refined surface finish.
The Final Product
Once the assembly and finishing processes were complete, the prototype was shipped to Nevada, Las Vegas, for functional testing. This final stage allowed the autonomous vehicle developers to conduct real-world trials and collect crucial data to refine their technology further.
The Future of 3D Printing in Automotive Prototyping
This project is a testament to the power of 3D printing in revolutionizing product development. By leveraging additive manufacturing, companies can drastically reduce lead times, lower costs, and iterate quickly. With the advancements in large-format 3D printing, the potential for even more ambitious automotive applications continues to grow.
At Lunia 3D, we remain committed to pushing the boundaries of what’s possible with 3D printing. Whether it’s for prototyping, small-batch production, or sustainable manufacturing, we’re excited to see where this technology takes us next.