Automotive

FDM 3D printing has become a game-changer for automotive enthusiasts and manufacturers alike, offering unprecedented flexibility in creating custom parts, repairing components, and even producing functional under-the-hood replacements. From cosmetic restorations like dashboard trim to high-heat engine bay components, FDM bridges the gap between prototyping and end-use manufacturing. With materials like Polymaker’s Fiberon™ line, automotive professionals and hobbyists can now produce parts that rival traditional manufacturing in strength, heat resistance, and precision—all from a desktop printer.

Lawrence Technological University Formula SAE Team uses Polymaker products to help build their car

Applications of FDM in Automotive

1. Cosmetic Repairs:

   • Interior Trim: Replace cracked dashboard panels, custom cup holders, or vintage steering wheel emblems.

   • Exterior Accents: Print aerodynamic splitters, mirror covers, or grille inserts.

   • Custom Accessories: Design unique shift knobs, phone mounts, or LED light housings.

2. Functional Components:

   • Jigs & Fixtures: Alignment tools for bodywork, brake line brackets, or welding guides.

   • Under-the-Hood: Air intake ducts, sensor mounts, or cable management clips.

   • Prototyping: Test-fit parts like turbocharger housings or suspension linkages before metal fabrication.

3. Performance Upgrades:

   • Lightweighting: Replace metal brackets with carbon-fiber-reinforced prints for weight reduction.

   • Heat Management: Heat-resistant ducts for turbo systems or coolant line brackets.

Polymaker Materials for Automotive Excellence

Polymaker’s Fiberon™ line delivers industrial-grade performance for demanding automotive applications, while other specialized filaments address niche needs.

1. Fiberon™ PPS-CF10

• Properties:

  • Heat deflection temperature (HDT) of 250°C+ (@0.45MPa), surpassing most thermoplastics.

  • Chemical resistance to fuels, oils, and solvents.

  • Metal-like stiffness with 10% carbon fiber reinforcement.

• Applications:

  • Turbocharger heat shields, engine bay brackets, and exhaust manifold covers.

  • Fuel line clips and sensor housings exposed to extreme heat.

2. Fiberon™ PA6-CF20

• Properties:

  • HDT of 215°C and exceptional rigidity with 20% carbon fiber.

  • Warp-Free™ technology for dimensional stability on open-frame printers.

• Applications:

  • Transmission mounts, throttle body adapters, and timing belt covers.

3. Fiberon™ PA612-CF15

• Properties:

  • Low moisture sensitivity relative to PA6 nylon for humid or wet environments.

  • Balanced strength and layer adhesion for complex geometries.

• Applications:

  • Fluid reservoirs, windshield washer pumps, and undercarriage components6.

4. Fiberon™ PA6-GF25

• Properties:

  • 25% glass fiber reinforcement for impact resistance.

  • HDT of 191°C and Warp-Free™ compatibility.

• Applications:

  • Bodywork plugs for molding widebody kits (e.g., Corvette fenders), bumper prototypes, and sanding jigs.

5. Fiberon™ PETG-ESD

• Properties:

  • Electrostatic discharge (ESD) protection for electronics.

  • High toughness and chemical resistance.

• Applications:

  • ECU enclosures, battery terminal covers, and sensor housings.

6. PolyMax™ PC

• Properties:

  • HDT of 140°C and UV resistance.

  • Exceptional impact strength (ISO 180/4A: 65 kJ/m²).

• Applications:

  • Headlight bezels, sunroof seals, and exterior trim requiring weather resistance.

Case Study: Widebody Kit Prototyping

Ivan Tampi Customs used Polymaker’s PA6-GF25 on a MAKEiT2x4 printer to produce full-scale fender plugs for Corvette widebody kits. The process:

1. 3D Scan: Capture the vehicle’s body shape digitally.

2. Design: Mirror the model for symmetrical counterparts.

3. Print: 5-day continuous print with a 0.6mm tungsten carbide nozzle at 285–300°C.

4. Post-Process: Sand and use as a mold plug for carbon fiber production.

Why FDM and Polymaker?

• Speed: Print replacement parts like door handles in hours, not weeks.

• Cost: A $50 spool of PA6-GF25 replaces $500+ clay modeling for body kits.

• Customization: Modify shift knobs or air vents to match unique designs.

• Durability: PPS-CF10 withstands engine bay heat better than aluminum in some cases.

Future of Automotive 3D Printing

With innovations like continuous fiber reinforcement and high-temperature composites, FDM is poised to manufacture end-use parts like alternator brackets and HVAC ducts. Polymaker’s Fiberon™ line exemplifies this shift, offering materials that meet automotive OEM standards while remaining accessible to garage-based creators.

By combining FDM’s flexibility and Polymaker’s material science, the automotive industry is entering an era where every repair, upgrade, or custom part is just a print away.