In the ever-evolving automotive industry, automakers are constantly seeking innovative ways to stay ahead of the competition. One such method gaining traction is additive manufacturing, a process that involves creating objects layer by layer. This technology is being utilized by automakers to produce vehicle parts and tooling faster and more cost-effectively than traditional methods.
General Motors Co. is at the forefront of this additive manufacturing revolution, with a dedicated Additive Industrialization Center located within its Global Technical Center in Warren. This facility houses over 20 industrial 3D printers that are capable of creating products from various metals and plastics. With a team of fewer than 20 individuals, the center works on thousands of projects annually, focusing on improving the vehicle manufacturing process and reimagining components for low-volume vehicles. Additionally, GM has another additive operation on campus with seven 3D printers available for engineers and designers to assist in vehicle development.
The benefits of additive manufacturing are clear, and automakers like GM are eager to expand its use throughout their operations. By utilizing this technology, GM aims to streamline production processes, reduce costs, and simplify manufacturing. The company’s executives have recognized the value that additive manufacturing brings to the business, prompting the rollout of a curriculum to educate employees on integrating this technology into their daily work.
At GM’s Additive Industrialization Center, the team is focused on exploring how additive manufacturing can be leveraged to redesign vehicle parts and tooling for improved efficiency. By consolidating multiple parts into one, the team aims to simplify assembly processes and reduce the number of components needed for production. This approach aligns with GM’s „winning with simplicity“ strategy, which aims to minimize design and engineering expenses while enhancing manufacturing efficiency.
GM’s Additive Industrialization Center is equipped with state-of-the-art machines that utilize various materials such as aluminum, steel, and polymer powders to create both metal and plastic parts. The team at the center is actively involved in creating tooling for plant use and developing prototype parts for vehicles. By focusing on tool replacement, the team has successfully reduced the weight of vehicle assembly tools by 50%, resulting in ergonomic benefits for plant workers.
In addition to tooling, GM has also integrated additive manufacturing into the production of vehicle components for low-volume vehicles. By utilizing 3D printing technology, the company has been able to create unique parts such as HVAC ducts for specific vehicle models. To further expand the use of additive manufacturing across the company, GM has developed a curriculum for engineers, designers, and other employees to familiarize them with the technology and its applications.
The automotive industry as a whole is recognizing the potential of additive manufacturing to revolutionize production processes and drive innovation. Consulting firm Wohlers Associates projects that the additive manufacturing industry will exceed $100 billion by 2032, marking a significant increase from current levels. While there are challenges such as the cost of industrial machines and materials, companies are embracing additive manufacturing for its ability to accelerate product development and testing.
Despite the benefits of additive manufacturing, there are still hurdles to overcome, such as material science issues and the time-consuming nature of layer-by-layer printing. However, the industry is optimistic about the potential of additive manufacturing to enhance speed, efficiency, and cost-effectiveness in automotive production. As automakers face increasing competition and the need for rapid innovation, additive manufacturing is poised to play a crucial role in driving the industry forward.