In the automotive industry, speed and flexibility are crucial. That’s why we’re proud to partner with Voxeljet, whose advanced 3D printing technologies are transforming development processes—from prototyping to production.
Their collaboration with Daimler is a prime example of this shift.
By using the VX1000 HSS industrial 3D printer and PA12 material, the team produced a prototype of the vehicle’s frontend (bumper), replacing 13 individually moulded parts with just 6 printed ones.
Thanks to integrated functionality within the printed parts, the assembly no longer required gluing or sanding. Instead, it relied on simple mechanical clips—a type of “click system.”
This means that during the design phase, key features such as connectors, alignment guides, and fastening geometries were already embedded into the 3D-printed structure. Most of the assembly solutions were built directly into the components—eliminating the need for post-processing or additional steps.
As a result, the entire assembly was achieved using mechanical joints, without adhesives or surface finishing such as sanding or edge preparation.
The parts varied significantly in size—the largest measured 971 x 375 x 152 mm, while the smallest was 292 x 98 x 65 mm. Despite this variation, all components achieved excellent accuracy within a tolerance of ±0.3%. The entire project was completed in three print jobs, with a total printing time of approximately 50 hours. There was no direct comparison with plastic injection molding in this case; however, using traditional methods, the same assembly would have required 11 separate components, each with its own mold and production process.
The benefits were immediately visible:
No need for expensive tooling – no up-front investment in moulds
Simplified assembly – fewer manual steps and reduced production time
Faster testing – parts were ready for aerodynamic testing without additional preparation
This approach:
- reduced the number of assembly steps,
- eliminated variability associated with manual processes,
and lowered overall prototyping costs and turnaround times.
Although this case focused on prototyping, the benefits of High-Speed Sintering (HSS) go even further.
In industries where low-volume production and design flexibility are key—such as special-purpose vehicles or airport shuttles—additive manufacturing is a highly effective alternative. Instead of investing in costly tooling, manufacturers can 3D print components like bumpers, finish or paint them, and bring them to market in small batches—quickly and cost-effectively.
At Chemets, we’re proud to be the regional representative for Voxeljet technologies, helping bring these advanced solutions closer to the engineers, designers, and manufacturers who need them.
The Mercedes frontend project is just one example proving that 3D printing is no longer limited to the lab—it’s thriving in real-world production.
👉 Curious how the VX1000 HSS system could support your development or production needs?
We’d be happy to guide you toward the most optimal solution.
