Additive manufacturing scale production is hindered, automation can be improved, breakthrough

3D printing technology has been used by Daimler for more than 25 years. There is a lot of experience in all the conventional methods of so-called additive manufacturing. At the Sindelfingen and Untertürkheim plants only, approximately 100,000 parts have been produced through the additive process and delivered to the development department or production facility. The current focus is on the production of models, visual objects and prototypes, tools and equipment. As 3D printing has great potential in prototyping, we will expand this area further. In the context of passenger car production, 3D printing technology is used to make tailor-made machines and equipment, such as adjustment and assembly aids, to achieve an optimal assembly process. At the same time, cost and weight can be reduced compared to conventionally manufactured equipment to improve, for example, ergonomics in the workplace.

Daimler bus implements 3D printing to produce custom Mercedes-Benz components

In the spare parts business, 3D printed parts are also interesting for special customer requirements or classic vehicles. This applies in particular to situations where traditional manufacturing processes no longer wear any tools or tools.

Since 2016, the parts business has used plastic parts manufactured by additives, for example in our commercial vehicle divisions, such as special-purpose vehicles such as Unimog. In addition, there are 30 different Mercedes-Benz truck spare parts approved for use with plastic 3D printers. In the bus sector, various special customer requirements are being produced through additive manufacturing – a very large growth rate. Due to the significant increase in the number of units produced in mass production by the Mercedes-Benz passenger car division, the additive manufacturing process is temporarily unable to meet this market.

Large-scale production using additive manufacturing methods is currently hampered by under-productivity. Due to the limited installation space in the "printer", the number of parts to be manufactured per system is limited. This process usually takes several hours to several days due to the layer structure. In addition, powdery resources are relatively expensive.

In the long run, it is possible to further break through large-scale production through continuous processes and increased automation of 3D printing.