Leading Automaker Develops Tens of Thousands of 3D Printed Parts — A Breakthrough Engine for Lightweighting and Rapid Iteration

With the rapid rise of new energy vehicles, groundbreaking innovation is reshaping the traditional boundaries of the automotive industry. Lightweight design, accelerated iteration, and performance breakthroughs have become key pillars of competitiveness for automakers. Metal 3D printing, once a prototyping tool confined to research labs, has now evolved into a strategic engine driving industrial transformation—its value clearly proven in real-world components.

Additive Manufacturing Unlocks Core Value in Automotive Innovation

Metal additive manufacturing is bringing revolutionary changes to core automotive components. Take aluminum alloy motor housings as an example: 3D printing enables integrated manufacturing, replacing traditional multi-part welding and assembly. The result?

· 20% reduction in component weight, improving EV range

· 50% fewer machining and assembly steps, streamlining the process

· Higher material utilization and lower raw material waste

In small- to medium-batch production or R&D prototyping stages, metal 3D printing eliminates the need for expensive die-casting molds, which often require hundreds of thousands or even millions in upfront investment. The development cycle is shortened by over 80%, delivering compelling economic advantages.

This technological leap is even more evident in structurally critical components like chassis parts. With topology optimization, metal 3D printing enables complex, non-conventional geometries and delivers over 20% weight reduction. By incorporating 0.3–0.5 mm ultra-thin wall composite structures, manufacturers can further reduce weight by 10–15% without compromising strength. Simulation results confirm that these parts meet demanding requirements for torsion, tensile, and flexural performance.

In addition to structural redesign, Han’s Laser is investing in new material development tailored to automotive applications. Its high-performance titanium alloys and high-toughness, high-strength aluminum alloys are breaking through traditional limitations in balancing strength and lightweight design—unlocking new potential for next-generation vehicles.

From Prototype to Real-World Impact: Releasing Transformative Potential

Rapid R&D Iteration
What once required 3–4 months for mold manufacturing can now be accomplished in a week with metal 3D printing. As the technology matures, more automakers are adopting it. Industry reports reveal that a leading carmaker has developed over tens of thousands of 3D printed parts, cutting prototype development cycles by more than 50%. This not only boosts speed but significantly reduces R&D costs and enhances the ability to test multiple design iterations quickly—dramatically improving response to shifting demands.

A Smart Revolution in Mold Manufacturing
The conformal cooling channels in injection and die-casting molds have long been a bottleneck in traditional manufacturing—but they’re a natural strength of 3D printing. These channels enable molds to cool 50% faster, with more uniform temperature distribution, raising the part’s first-pass yield to over 99%.

Beyond better cooling, 3D printed molds offer performance upgrades, structural optimization, and crack and deformation resistance. Mold lifespan is significantly extended, reducing both maintenance costs and production downtime.

Core Value and Future Vision: Redefining Intelligent Auto Manufacturing

The core value of metal 3D printing is being increasingly realized in the automotive world—from prototyping to production deployment. It brings:

· Revolutionized design concepts that drive structural integration and lightweighting

· Simplified processes that cut costs across the product lifecycle

· Accelerated product launches and agile market responsiveness

· Flexible support for custom and rapid development needs

Metal 3D printing is set to become an indispensable driver of future automotive manufacturing. Han’s Laser remains committed to innovation, advancing core technologies, and expanding the application of 3D printing in real-world production. As this technology continues to evolve, it will empower the automotive industry as a core engine of next-generation manufacturing innovation.