Automotive 3D Printing Could Change The Way Carmakers Do Repairs

Automotive OEMs face increasing pressure to improve their supply chains, not only to reduce costs and improve efficiency but to meet environmental demands for a lower carbon footprint. Traditional inventory models with centralized warehouses lead to high storage costs, delays, and emissions tied to transportation. As a solution, some forward-thinking OEMs are turning to digital inventories combined with automotive 3D printing, allowing them to print spare parts on demand and locally, thus minimizing logistical burdens and aligning with sustainability goals.

The digital inventory model allows parts to be stored in a virtual form until needed. By integrating 3D printing capabilities, OEMs gain several key advantages. Unlike traditional inventories, which require physical storage, digital inventories allow parts to be manufactured as needed. This approach significantly cuts lead times and minimizes the costs associated with storing and maintaining extensive physical inventories. Localized 3D printing production can protect OEMs from global supply chain disruptions. Instead of depending on far-reaching distribution networks, OEMs can produce parts locally, thereby enhancing resilience to geopolitical and environmental disruptions.

Additionally, The environmental impact of manufacturing and logistics can be substantial. Digital inventories paired with 3D printing not only reduce the need for transportation but also cut down on material waste. For instance, printing components only when required minimizes both production waste and the associated emissions, leading to a more sustainable supply chain.

So far, there are only a handful of firms, such as Auto Additive and Würth Additive, looking to implement such a model in the automotive space. Autentica is another of a growing number of companies aiding OEMs in the digital inventory transformation. Autentica’s approach to digital inventories for the automotive sector centers around a secure platform that combines blockchain technology with non-fungible tokens (NFTs), enabling OEMs to protect and trace their digital assets throughout the supply chain.

In an interview, Autentica CEO Irma Gilbert noted that traditional inventory models are often fraught with inefficiencies and hidden costs, pointing to her own past experiences needing to travel internationally for spare parts due to a lack of local availability. “I realized there had to be a better way,” she explained, leading her to establish Autentica as a solution for digitalizing spare parts with cutting-edge security measures.

Through its NFT-backed platform, Autentica addresses a fundamental challenge in digital part distribution: intellectual property (IP) security. By embedding tokens that secure CAD files, Autentica allows OEMs to distribute digital blueprints safely, ensuring files are used only by authorized service providers. Gilbert underscores the importance of this technology, stating, “NFTs provide a unique identifier for each file, ensuring that the digital asset is protected and can only be used as intended by the OEM.”

The technology enables a seamless process where service providers receive encrypted, streamable files that can be used immediately to print needed parts. Autentica’s approach has also led to significant interest beyond automotive, with OEMs in aerospace and defense also considering similar applications. “The biggest hurdle is changing the traditional mindset of manufacturers,” Gilbert observes, but she notes that early adopters in the automotive sector are beginning to realize substantial operational improvements.

Industry-wide Challenges for Automotive 3D Printing

The broader adoption of digital inventories and 3D printing in the automotive repair industry has raised questions about regulatory oversight and safety standards. A recent 2023 report from the 3D Printing in Auto Repair Task Force, led by industry veterans, highlights the need for “a regulatory body or governing authority” to set and enforce safety and quality standards for 3D-printed parts. This body would play a critical role in ensuring that parts manufactured on demand meet stringent quality standards—especially crucial for parts used in automotive repairs, where failure could result in severe safety risks.

Insurance companies also face unique considerations with 3D-printed parts. On the positive side, quicker repairs facilitated by on-demand part production lead to shorter vehicle downtimes, which translates into reduced car rental expenses for insurers. However, the task force report cautions that if substandard 3D-printed parts contribute to accidents, insurers may face higher claims and settlement costs. This delicate balance between efficiency and safety underscores the need for OEMs to adopt rigorous quality controls in digital inventories to maintain insurer and consumer confidence.

Automotive 3D Printing: A Case in Point

In 2022, General Motors (GM) demonstrated just how powerful 3D printing can be to solve supply chain issues during the rollout for the Chevrolet Tahoe. Facing a last-minute design modification that required an additional part—known as a spoiler closeout seal—GM’s engineers needed a solution that wouldn’t delay the delivery of around 30,000 vehicles. Traditional manufacturing methods, such as injection molding, would have taken too long to produce the necessary 60,000 parts, putting deliveries at risk.

To solve this, GM turned to AM, specifically HP’s Multi Jet Fusion (MJF) technology operated by GKN Additive’s Forecast 3D division. Within just five weeks, GKN Additive produced and finished all 60,000 seals, helping GM avoid costly delays. This achievement highlights the ability of AM to provide agile, on-demand solutions for manufacturing bottlenecks, proving that the technology has advanced well beyond prototyping into true, scalable production.

GM’s use of 3D printing in this case demonstrates the broader potential of AM for automotive OEMs. If OEMs permitted certified third-party providers to 3D print replacement and repair parts, the industry could replicate GM’s success on a wider scale. The shift to distributed, on-demand part production could reduce lead times, lower inventory costs, and improve overall supply chain resilience across the automotive sector.

The Future of Digital Inventories in Automotive 3D Printing

The adoption of digital inventories with 3D printing holds transformative potential for the automotive industry. By embracing this model, OEMs can benefit from flexible production that can be tailored to specific geographic needs and product requirements. The technology not only allows OEMs to reduce costs but also enhances their ability to respond quickly to market changes and customer demands.

Moreover, the sustainability benefits are significant. As more automakers commit to carbon reduction goals, digital inventories with 3D printing offer a practical means to meet these objectives. Localized 3D printing reduces transportation emissions, and the efficiency of additive manufacturing processes minimizes material waste.

Gilbert remains optimistic about the future of Autentica’s digital inventory solutions, underscoring the platform’s potential to reshape not only automotive manufacturing but a broad spectrum of industries. “We’re currently negotiating with major players in aerospace and defense, and these sectors are beginning to recognize the value of our platform,” she noted. As these sectors adopt similar technologies, the cumulative impact on global manufacturing sustainability could be profound.

As digital inventories gain traction in the automotive sector, companies like Autentica illustrate the benefits of a decentralized, on-demand supply model. With the dual advantages of reduced costs and enhanced sustainability, this approach aligns well with the needs of modern automotive OEMs. By leveraging the latest in blockchain, NFT, and automotive 3D printing technologies, Autentica sets a powerful precedent for others to follow, fostering a future where vehicle manufacturing is not only more efficient but also more resilient and environmentally conscious.