82% Weight Reduction! How EP SLS 3D Printing Technology Helps New Energy Vehicles “Travel Light”

According to the Ministry of Industry and Information Technology, China has ranked first in global new energy vehicle (NEV) production and sales for ten consecutive years. In 2024, annual output and sales both exceeded 12.8 million units, with exports reaching over 70 countries and regions.

Within this booming industry, additive manufacturing is emerging as a key driver of R&D and production innovation. EP’s Selective Laser Sintering (SLS) 3D printing technology, with its unique advantages, is empowering the NEV sector from design to manufacturing.

Rapid Prototyping: Accelerating R&D Cycles

In NEV development, quick validation of appearance, assembly, and ergonomics directly affects project timelines. EP’s SLS 3D printing delivers high precision + fast turnaround, offering an efficient solution for prototype parts.

· Wheel Hub Cover: Printed in Precimid1172Pro bright white PA12, combining dimensional accuracy, surface quality, mechanical strength, and durability. Supports paint, electroplating, and other post-processing to achieve 1:1 simulation of mass-production parts.

· Commercial Vehicle Light Housing: EP’s P550DL system (build volume 550 × 550 × 850 mm) printed 15 housings in just 30 hours, significantly outperforming traditional methods. Precimid1172Pro PA12 provided excellent all-round performance for mechanical testing.

Lightweighting + Safety: Up to 82% Weight Reduction

For specialized vehicles, race cars, and autonomous platforms requiring low-volume, high-performance parts, EP’s SLS enables complex geometries and material-driven breakthroughs.

· Beijing Institute of Technology’s “Triple Crown” Formula Racing Team:

o Adopted SLS with Precimid1171 FR flame-retardant nylon.

o Achieved 36.7% weight reduction on battery module brackets (from 300 g fiberglass to 190 g SLS nylon).

o Certified UL94-V0 flame retardancy, ensuring both lightweighting and high safety.

· Tongji University Racing Car:

o Integrated nearly 200 SLS parts across the entire vehicle, covering battery modules, controllers, aero components, cooling systems, and structural brackets.

o Results: 195 kg total weight, 110 km/h top speed, 0–100 km/h in 3.6 seconds.

o Key upgrades included 1 kg weight reduction in the battery module frame, 15% weight reduction in skeleton structures, and optimized complex water jackets and ducts with superior fatigue resistance.

· Dubai Autonomous Police Vehicle (MICROPOLIS):

o Printed large front body parts using Precimid1172Pro GF30 glass-fiber reinforced nylon.

o Delivery time cut from 4 days to 2 days (+50% efficiency).

o Weight reduced from 27 kg (metal) to 4 kg (SLS), an 82% reduction, dramatically lowering energy consumption.

o Simplified workflow: direct print from design, eliminating cutting, bending, welding, and assembly.

Tooling & Fixtures: 73% Cost Reduction

In mass production, tooling and fixtures directly impact efficiency and costs. EP’s SLS 3D printing delivered transformative gains for an automotive parts manufacturer supplying Hyundai’s global plants.

· Cycle Time: Reduced from 5.5 days (sand-cast aluminum) to 2.5 days (SLS nylon), a 55% improvement.

· Cost: Cut from USD 2,060 to USD 550 per set, saving 73%.

· Yield: Significantly improved by eliminating precision defects common in traditional casting.

A New Paradigm for NEV Manufacturing

From R&D prototyping, to low-volume lightweight flame-retardant components, to mass-production tooling optimization, EP’s SLS 3D printing demonstrates the transformative power of additive manufacturing for NEVs. As materials continue to advance and machine efficiency improves, SLS technology will further accelerate the industry’s march toward lighter, faster, and safer vehicles, injecting new vitality into NEV innovation.