The automotive industry has been driving forward new manufacturing technologies for decades. In addition to large-scale production, prototyping, design validation, and shorter development cycles play a central role. Additive manufacturing – commonly known as 3D printing – has established itself firmly in this field in recent years.
Mercedes-Benz is using voxeljet’s High Speed Sintering (HSS) process to demonstrate how large-format plastic components can be manufactured more efficiently and intelligently. Example: the front bumper of the Mercedes-Benz C220d – traditionally manufactured using injection molding, but significantly more flexible in 3D printing for development and presentation purposes.
But can a large-format car body component even be manufactured dimensionally accurate, stable, and economically using the HSS process?
Where injection molding and SLS reach their limits
Conventionally, bumpers are produced using injection molding—ideal for large series, with high precision and low costs per part. However, the initial tooling costs are expensive, usually in the five-figure range. In addition, the bumper originally consisted of 11 injection-molded individual parts, which is rather impractical for prototyping or design studies.
Selective laser sintering (SLS) is also established in the industry. However, it has its limitations when it comes to large-format components:
- Build volume: Many small jobs instead of one large one.
- Productivity: Spot processing slows down the process.
- Costs: For large parts, the time and cost involved increase significantly.
Accordingly, although the bumper could be produced in the SLS, it was only possible to manufacture ten individual components due to limited build volume.
3D printing with the VX1000 HSS
Thanks to its combination of full surface radiation, sophisticated thermal management, industrial print heads, and large build volume, HSS was the perfect choice for large plastic parts such as this bumper.
Mercedes-Benz decided to use the High Speed Sintering (HSS) process in collaboration with voxeljet. Printing was carried out on a VX1000 HSS, which, with a build volume of 1,000 x 550 x 190 mm³, is specially designed for the series production of small plastic components as well as very large geometries.
Key technical data
- Dimensions: 1801 x 581 x 603 mm
- Material: polyamide 12 (PA12)
- Assembly volume:5 liters
- Reduction in number of parts: from 11 to 6 parts
- Process optimization: digital plug connections for easy assembly and good fit
Advantages of the HSS process over injection molding and SLS
- No tooling costs: Ideal for prototypes and small series.
- Part consolidation: Fewer individual parts, less assembly.
- Dimensional accuracy: Comparable to injection molding.
- Scalability: Large parts in just a few build jobs.
- Design freedom: Function integration directly in the print, including rapid design optimization.
Technical challenges
Manufacturing such a large component using the HSS process had its challenges:
Build volume:
The bumper exceeded the actual build height of the VX1000 HSS. However, this problem was solved by cleverly dividing the CAD model.
Warping & dimensional accuracy:
Large parts tend to warp during printing or shrink during cooling. This is where the intelligent temperature management and process stability of the VX1000 HSS came into play: precise adjustment options result in perfect dimensional accuracy within the tolerances.
Assembly:
Thanks to the design of appropriate plug connections, assembly was effortless and the assembly retains its shape stably.
Relevance for the automotive industry
The project illustrates that HSS can be used to produce prototypes in days rather than weeks. Changes do not require new tools; all adjustments are made digitally.
New applications are emerging for motorists, particularly for:
- Small series (e.g., motorsports, special models),
- Aftermarket parts (on-demand spare parts),
- Design studies (rapid iteration),
- Function integration (sensor mounts, clips).
Mercedes-Benz has already demonstrated in previous projects that additive manufacturing has long been of strategic importance in the automotive industry. As Jasmin Eichler, Head of Future Technologies at Daimler AG, emphasizes:
Additive Manufacturing is also suitable for smallest-series production of new vehicles (limited editions). Systematic development of the parts specifically for 3D printing means that the production costs can be further reduced and the quality optimised. 3D printing also makes particular sense during the advance development of vehicles. The low numbers required can often be produced more cost-effectively, and faster, with Additive Manufacturing than with conventional production processes.
Jasmin Eichler
Director Future Technologies, Daimler AG
Conclusion: Additive manufacturing as the key to greater flexibility
The 3D-printed Mercedes-Benz front bumper impressively demonstrates the capabilities of the VX1000 HSS. For Mercedes-Benz, it was proof that even large-format plastic parts can be produced additively with dimensional accuracy, stability, and cost-effectiveness.
Injection molding remains the standard for large series production. However, additive manufacturing is establishing itself as the key to flexibility, sustainability, and rapid innovation in prototyping, small series, and niche markets. Ultimately, highly productive systems such as the VX1000HSS are also increasing the number of components that can be manufactured economically compared to injection molding.
