Manuscript Title:

TRANSFORMATIVE IMPACT OF METAL ADDITIVE MANUFACTURING ON AUTOMOTIVE DESIGN AND PRODUCTION

Author:

B. ANUSHA, V. MOKSHAGNA SAI, M.L. PAVAN KISHORE, M. AVINASH

DOI Number:

DOI:10.5281/zenodo.15876301

Published : 2025-07-10

About the author(s)

1. B. ANUSHA - Graduate Student, Department of Mechatronics Engineering, Faculty of Science and Technology, ICFAI Foundation for Higher Education, IFHE (ICFAI Tech), Hyderabad, India.
2. V. MOKSHAGNA SAI - Graduate Student, Department of Mechatronics Engineering, Faculty of Science and Technology, ICFAI Foundation for Higher Education, IFHE (ICFAI Tech), Hyderabad, India.
3. M.L. PAVAN KISHORE - Assistant Professor, Department of Mechanical Engineering, Faculty of Science and Technology, ICFAI Foundation for Higher Education, IFHE (ICFAI Tech), Hyderabad, India.
4. M. AVINASH - Associate Professor, Department of Mechanical Engineering, Faculty of Science and Technology, ICFAI Foundation for Higher Education, IFHE (ICFAI Tech), Hyderabad, India.

Full Text : PDF

Abstract

The automobile industry faces daily challenges with design modifications and technological advancements compelling companies to develop innovative models with rapid turnaround times, necessitating frequent tool adjustments. Within this highly competitive field, reducing time-to-market represents a critical advantage. Additive manufacturing emerges as an effective solution, facilitating flexible production of customized products without significantly influencing costs or lead times. Vehicle manufacturers continuously develop new models influenced by design trends and technological progress, balancing aesthetics, aerodynamics, safety, and weight reduction considerations. This constant evolution demands new tooling for body panels and technical components. Mass production techniques assist the automobile sector in transforming concepts into vehicles efficiently. Manufacturers can enhance research and development efficiency, bringing products to market more quickly. A significant benefit of metal additive manufacturing in automobiles involves creating intricate lightweight structures that maintain excellent rigidity. Vehicle part weight can be substantially reduced by leveraging AM capabilities to produce geometrically complex components while preserving structural integrity. Various processes including Selective Laser Melting, Electron Beam Melting, Laser Deposition Welding, Direct Metal Deposition, and LENS are utilized across automobile industries to improve production rates and quality. The adoption of metal 3D printed spare parts, jigs, and fixtures by prestigious brands like AUDI, Rolls Royce, and Porsche demonstrates the promising future of this technology in the automotive sector. This report examines current applications and future prospects of metal additive manufacturing in automobile production, addressing aims, objectives, production methods, and challenges associated with this advanced technology.


Keywords

Additive Manufacturing, Automotive Industry, Design Innovation, Lightweight Structures, Metal 3d Printing, Production Efficiency, Tooling Advancements.