Driving Automotive Innovation with From Concept
Validation to Production Support

Bring design intent off the screen and into stakeholder reviews before tooling decisions are locked. Stratasys PolyJet 3D printers enable design teams to produce high-fidelity concept models with color, texture, transparency, rigid and flexible features, and CMF detail in a single workflow.

Best Fit Technology:

• PolyJet: Leverage full color and multiple materials for highly realistic concept modeling.
• SLA: Print large, smooth models when size, surface quality, and minimal post processing are critical.

Benefits:

• Reduce manual work on full-color, multi material models to reduce time by up to 75% and costs by up to 85%.
• Improve communication between design, engineering, suppliers, and decision-makers.
• Validate aesthetics, ergonomics, proportions, and CMF decisions earlier in the design cycle.

De-risk assemblies before hard tooling by printing functional prototypes that engineering teams can hold, install, inspect, and test. Check fit on assemblies, perform ergonomic reviews, and test fixtures quickly, without the long lead times of machining.

Best Fit Techology:

• PolyJet: Produce multi-material prototypes for high realism, including transparent, color, and flexible materials.
• SLA: Produce large-scale accurate prototypes when surface finish and fine detail are priorities

Benefits:

• Shorten production cycles by multiple weeks.
• Validate assembly interfaces, clearances, and service access before tooling.
• Build large prototypes in fewer sections to reduce assembly time and fit-up variation.

Accurate aerodynamic testing depends on models that match CAD intent, capture fine details, and stand up to demanding test environments.

Best Fit Technology:
SLA: Produce high-precision wind tunnel models with smooth surfaces and complex geometry.

Benefits:

• Reduce prototype costs by up to 50%.
• Create complex aerodynamic features and internal channels directly in the print.
• Enable faster design-test-refine cycles alongside CFD and physical validation.

Replace long-lead machined tooling with printed mold tools, inserts, composite layup tools, sacrificial cores, thermoforming tools, trim fixtures, drill fixtures, and master tooling. This is especially valuable for prototype tooling, low-volume production, custom vehicle programs, and high-mix manufacturing environments where hard tooling cost and lead time is difficult to justify.

Best Fit Technology:

• PolyJet: Use Digital ABS Plus to produce heat
  resistant, realistic prototype tooling.
• SLA: Produce smooth, accurate master patterns
  and rapid tooling.

Benefits:

• Reduce tooling lead times from weeks or months to days in many applications.
• Lower cost for prototype, low-volume, and high mix tooling.
• Validate molded or composite part designs before committing to hard tooling.

Accelerate investment casting by printing accurate master patterns directly from CAD instead of producing wax tooling. This helps foundries and automotive engineering teams produce complex metal components faster, especially for low-volume, prototype, pre-production, or performance-critical parts where tooling cost and lead time are major constraints.

Best Fit Technology:
SLA: Support intricate patterns with strong surface quality and dimensional accuracy.

Benefits:

• Create master patterns up to 75% faster than CNC machining and wax injection workflows.
• Create intricate geometries that are difficult or uneconomical with conventional wax tooling or CNC-machined patterns.
• Support faster design iteration for small-batch and complex metal components.

Stratasys 3D printing solutions can also support the automotive manufacturing floor with jigs, fixtures connector housings, and low volume production parts to improve efficiency, precision, ergonomics, and repeatability.