Additive Manufacturing Opportunities In Automotive – 2018

Report # SMP-AM-AUTO-0618
Published June 20, 2018

In 2016, SmarTech Publishing released the most complete and thorough analysis and forecast of  automotive additive manufacturing. Two years later many new events have continued to propel the use of 3D printing technology into the future of automotive production. This new 200-page 2018 report confirms the 2016 forecast, while also expanding it  with new high-value and high-volume applications and technologies that have emerged.

Automotive industry stakeholders worldwide are now racing toward full industrialization and integration of the AM process within their end-to-end production workflow, beginning with software and materials, passing through the actual AM hardware, and ending with services and a growing number of possible applications. 3D printing is thus well positioned to expand its use as the primary technology for automotive prototyping as well as tooling, while also establishing a stronger than ever opportunity for serial and mass customized part production.

This third dedicated study of automotive additive manufacturing expands coverage to consider the greater long term potential for additive manufacturing as a key production technology for the massive global automotive industry, paving the way to widespread adoption of both metal and polymer AM technologies. This comprehensive report includes:

  • Ten-year 3D printing opportunity and market data forecasts in volume and value terms for automotive additive manufacturing. These coverhardware, materials, software, services and overall printed parts value – illustrated with over 80 charts and exhibits.
  • Expanded market data to include key metrics at a country level, better capturing the regional attitudes towards introducing AM in the production workflow for prototyping, tooling and final parts.
  • Complete lists and descriptions of key AM hardware and AM materials (both polymer and metal alloys) used in automotive AM, including upcoming production-ready technologies.
  • Complete analysis of software used in the end-to-end automotive production cycle, in light of recent advanced in generative design software and PLM software solutions.
  • The latest trailing twenty-four months activity and competitive analysis to reflect the rapidly evolving landscape in which major automakers, automotive tier 1 and tier 2 suppliers and “application agnostic” 3D printing service are finding new cost-effective solutions through AM adoption.
  • Complete and detailed analysis and forecast of the potential for final parts production through AM

This is by far the most extensive exploration of where the opportunities will be found in automotive additive manufacturing for prototypes, tools and final parts in the next decade.

Additive Manufacturing Automotive Forecast

 

Chapter One: Automotive Additive Manufacturing is Coming of Age
1.1 Automotive as the Inflection Point for AM
1.2 The Global AM Automotive Market Today
1.2.1 Fuel Economy, Electric Mobility and AM
1.1.2.1 Electric Smart Mobility and AM
1.2.1.2 Mass Reduction Trends for Today
1.3 Geographic Considerations for Automotive AM Applications
1.3.1 North America
1.3.2 Asia
1.3.3 Europe
1.4 Material Factors
1.4.1 Metal AM Moving to Batch Production
1.4.2 Long Term Ceramics AM Opportunities
1.4.3 Additive Manufacture of Composites for Automobiles Making Strides
1.5 Software Factors: The Drive for More AM Automation and Networking
1.5.1 From Prototyping to Production and Beyond
1.5.2 Indirect AM processes as a key intermediate step
1.5.3 Automating the End-to-end Process
1.5.4 Automating Continuous Layer FDM
1.5.4.1 Automating Polymer Powder Bed Fusion Processes
1.5.4.2 Automating Metal Powder Bed Fusion Processes
1.5.4.3 Automating Metal Deposition Processes
1.5.4.4 Automating Photopolymerization Processes
1.5.4.5 Automating Binder Jetting Processes
1.6 Primary AM Application Segments in Automotive
1.7 Most Influential Alliances in Automotive AM
1.7.1 Stratasys/Siemens/Ford
1.7.2 BMW/Carbon/Desktop Metal
1.7.4 Daimler/EOS
1.7.5 GM/Autodesk
1.7.6 Divergent/PSA/SLM Solutions (Audi)
1.7.7 Local Motors/Cincinnati Inc/IBM
1.8 Forecasting in this Report
1.8.1 Discussion of Methodology
1.8.2 Important Methodology Changes versus Previous Studies
1.9 Key Points from this Chapter
Chapter Two: AM Technologies and Their Applications in Automotive Production
2.1 Metal AM Technologies Moving into Production
2.1.1 Metal Powder Bed Fusion Hardware for Automotive AM
2.1.2 Relevant New Metal PBF Systems in Development
2.1.3 Metal Binder Jetting/MIM Bound Powder Technologies for Automotive Part Production
2.1.3.1 Next Gen Binder Jetting
2.1.4 Are There Metal Deposition Technologies in the Future of Automotive AM?
2.1.4.1 Types of Metal Deposition Technologies
2.1.4.2 Blown Powder (cold spray)
2.2 Thermopolymer AM Technologies Used in the Automotive Segment
2.2.1 Powder Bed Fusion Technologies for Automotive Applications
2.2.1.1 SLS for Lowering Part Production Costs Automotive
2.2.1.2 MJF/HSS in Automotive
2.2.2 Thermopolymer extrusion applications
2.2.2.1 Continuous Fiber Composites Extrusion
2.2.2.2 Chopped Fiber Composites Extrusion
2.2.2.3 Robotic Arm Deposition
2.2.2.4 Large-scale extrusion and deposition
2.3 Photopolymer-based AM Technologies Used in Automotive
2.3.1 Large-scale SLA and DLP automotive applications
2.3.2 High-speed Continuous Technologies (CLIP and cDLM) and their Automotive Applications
2.3.3 Material jetting for automotive applications
2.4 Forecast of Professional AM Hardware Demand and Sales in Automotive
2.5 Low-cost Technologies
2.5.1 FFF
2.5.2 SLA
2.5.3 Benchtop PBF
2.5.4 Production Cells for Serial Manufacturing
2.6 Forecast for Low-cost AM Hardware in Automotive
2.7 Composites
2.7.1 Key Continuous Fiber Technologies for Automotive Applications
2.8 Ten-year Forecast for AM Hardware in the Automotive Segment
2.8.1 Ten-year Forecast for Metal AM Hardware in Automotive
2.8.2 Ten-year Forecast for Polymer (Photopolymerization, PBF, Extrusion)
2.8.3 Geographic Considerations and Regional Forecast for AM Hardware in Automotive
2.9 Key Points from this Chapter
Chapter Three: Materials and Software for Automotive Manufacturing
3.1 Polymers and Composites Used In Automotive Part Production
3.1.1 Thermopolymer Filaments
3.1.2 Thermopolymer Powders
3.1.3 Liquid Photopolymer Resins
3.2 Metals and Alloys used in automotive part production
3.2.1 Titanium and titanium alloys
3.2.2 Aluminum and Aluminum Alloys in as a Key to Unlock Automotive AM Production
3.2.2.1 Metal AM in Automotive Driven by Demand for Aluminum
3.2.2.2 Steel and Steel Alloys in Automotive
3.2.2.3 Steel Alloys for Automotive AM
3.2.3 Nickel and Inconel Superalloys in the Automotive Industry
3.3 Ten-year Forecast for Materials in Automotive AM
3.3.1 Forecast for Metal Materials in Automotive AM
3.3.2 Forecast for Polymer and Composite Materials in Automotive AM
3.4 Regional Distribution of AM Materials for Automotive Applications
3.5 Types of AM Software for Automotive AM
3.5.1 CAD
3.5.2 CAE
3.5.3 CAM
3.5.4 MES
3.5.5 PLM
3.5.6 Simulation and Process Monitoring
3.6 AM-Specific Software Capabilities to Benefit Automotive Development/Manufacturing
3.6.1 Parametric Automotive Design
3.6.2 Topology Optimization for Automotive Light weighting
3.6.3 Trabecular and Lattice Structures
3.6.4 Generative Software used in Automotive Part Design
3.6.5 3D Scanning, Inspection and Reverse Engineering Software
3.6.6 Additive Manufacturing Networks Seeking to Provide Digital Mass Production and Mass Customized Outsourcing with 3D Printing
3.7 Ten-year Software Forecast
3.8 Key Points from this Chapter
Chapter Four: Services and Applications for Automotive Part Production by AM
4.1 AM Service Bureaus Providing Automotive Production Capabilities
4.1.1 Visions for the Automotive AM Factory of Tomorrow
4.1.1.1 Concept Laser’s Factory of Tomorrow
4.1.1.2 EOS NextGenAM
4.1.1.3 Additive Industries’ MetalFAB1
4.1.1.4 Renishaw’s Automated Workflow
4.1.1.5 DMG Mori’s Path to Digitalization
4.1.2 Polymer AM Vendor Strategies for Adapting 3D Printers to Factory Environments
4.1.2.1 Stratasys Infinity, Continuous Build and Composite Demonstrator Platforms
4.1.2.2 Carbon’s SpeedCell
4.1.2.3 3D Systems’ Figure 4
4.2 Ten-year Forecast for AM Services
4.3 Relevant AM Applications Case Histories in Automotive
4.3.1 Automotive OEM’s
4.3.2 Rapid Prototyping
4.3.2.1 Better Functional Prototyping – Recent Relevant Cases
4.3.3 Forecast for Metal and Polymer Prototypes Global Demand
4.3.4 Tooling, Jigs, Fixtures, Molds and Other Indirect Manufacturing Cases
4.3.4.1 Printed Casting Patterns for Functional Prototypes
4.3.4.2 3D printing for composite tooling
4.3.5 Forecast for AM Revenues in Tooling
4.4 AM for Final Parts Production
4.4.1 One-off Concepts, Motorsports, Limited Series And Custom Production (Short Batch)
4.4.1.1 Formula 1 Openly Adopts AM
4.4.1.2 Wheels from space
4.4.2 Part replacement and obsolescence management, including classic car part reproduction (medium batch)
4.4.2.1 Metal and Polymer Spare Parts at Daimler-Benz
4.4.2.2 Metal spare parts at Audi
4.4.2.3 Polymer Spare Parts at Volvo Construction Equipment
4.4.2.4 Obsolescence Management at Porsche (Volkswagen)
4.4.3 Mass Production and Mass Customization Cases (Medium Batch)
4.4.3.1 High-end car parts production
4.4.3.2 Mass customization
4.4.4 Mass Production (Large Batch)
4.4.4.1 Moving into the factory
4.5 Ten-year Forecast for AM in Final Parts Automotive Production
Key Points from This Chapter
About SmarTech Publishing
About the Analyst
Acronyms and Abbreviations Used In this Report
List of Exhibits
Exhibit 1-1: Exploring 3D Printing in Automobile Technology Development Areas
Exhibit 1-2: Total Projected Automotive 3D Printing Opportunities, by Category, 2014-2026
Exhibit 1-3: Total AM Market Value for Automotive
Exhibit 1-4: Expected Year on Year Growth Rate for AM Automotive
Exhibit 1-5: Estimated CAGR rates for Automotive AM Segments
Exhibit 1-6: Potential Polymer and Thermoplastic Composite Applications for 3D Printing in Automobiles to Reduce Weight
Exhibit 1-7: Summary of Potentially Disruptive AM Composite Manufacturing Technologies for the Automotive Industry
Exhibit 1-8: Automotive Industry AM Adoption Model
Exhibit 2-1: Leading metal AM Systems used in automotive
Exhibit 2-2: Leading metal binder jetting and bound metal systems
Exhibit 2-3: Leading metal deposition systems
Exhibit 2-4: Leading thermoplastic powder bed fusion manufacturers
Exhibit 2-5: Thermoplastic extrusion manufacturers, technologies and key materials
Exhibit 2-6: Leading photopolymerization system manufacturers for automotive AM
Exhibit 2-7: Professional AM Hardware Unit Sales Forecast in Automotive 2017 - 2028
Exhibit 2-8: Professional AM Hardware Revenues Forecast ($USM) in Automotive 2017 - 2028
Exhibit 2-9: Forecast of Low Cost AM Hardware Unit Sales in Automotive 2017-2028
Exhibit 2-10: Forecast of Low Cost AM Hardware Revenues ($USM) in Automotive 2017-2028
Exhibit 2-11: Forecast of Total Yearly AM Hardware Units Sales in Automotive 2017 - 2028
Exhibit 2-12: Forecast of Total Yearly AM Hardware Revenues ($USM) in Automotive 2017 - 2028
Exhibit 2-13: Expected YoY Growth Rates and Growth Trend for AM Hardware Spending in Automotive
Exhibit 2-14: Forecasted Growth Rates for Hardware Sales in Automotive by Technology 2018 - 2028
Exhibit 2-15: Cumulative Unit Sales of AM Hardware in Automotive (2017 – 2028)
Exhibit 2-16: Forecast of Yearly Metal AM Hardware Unit Sales in Automotive 2017 - 2028
Exhibit 2-17: Forecast of Yearly Metal AM Hardware Revenues ($USM) in Automotive 2017 - 2028
Exhibit 2-18: Forecast of Yearly Polymer AM Hardware Unit Sales in Automotive 2017 - 2028
Exhibit 2-19: Forecast of Yearly Metal AM Hardware Sales Revenues ($USM) in Automotive 2017 - 2028
Exhibit 2-20: Comparison Between Metal and Polymer AM Hardware Revenues Growth Trends in Automotive
Exhibit 2-21: Comparison Between Low-cost and Professional AM Hardware Unit Sales Growth Trends in Automotive
Exhibit 2-22: Comparison Between Low-cost and Professional AM Hardware Revenues Growth Trends in Automotive
Exhibit 2-23: Geographic Distribution of AM Hardware Unit Sales in Automotive 2017-2028
Exhibit 2-24: Geographic Distribution of AM Hardware Revenues in Automotive 2017-2028.
Exhibit 3-1: Comparison Between Demand of Polymer Materials in Automotive (Kg) 2017 - 2028
Exhibit 3-2: Comparison Between Demand of Thermoplastic Filament Materials (Kg) for Extrusion Technologies in Automotive 2017- 2028
Exhibit 3-3: Primary Thermoplastic Powder Materials Used in Powder Bed Fusion Processes for Automotive Applications
Exhibit 3-4: Comparison Between Demand of Thermoplastic Powder Polymer Materials (Kg) for Powder Bed Fusion Technologies in Automotive 2017 - 2028
Exhibit 3-5: Comparison Between Demand of Photopolymer Resin Materials (Kg) for Photopolymerization Technologies in Automotive 2017 - 2028
Exhibit 3-6: Primary Materials f
Exhibit 3-15: Overall AM Material Revenues YoY Growth and Growth Trend (2017 – 2028)
Exhibit 3-16: Comparison Between Growth Trends for Metal and Polymer Materials in Automotive AM
Exhibit 3-17: Demand for Metal Materials in Automotive AM by Metal Alloy Type (Kg) 2017 - 2028
Exhibit 3-18: Revenues for Metal Materials in Automotive AM by Metal Alloy Type ($USM) 2017 - 2028
Exhibit 3-19: Thermoplastic Filament Demand in Automotive AM (Kg) 2017 - 2028
Exhibit 3-20: Thermoplastic Filament Revenues in Automotive AM ($USM) 2017 – 2028
Exhibit 3-21: Photopolymer Resin Demand in Automotive AM (Kg) 2017 - 2028
Exhibit 3-22: Photopolymer Resin Revenues in Automotive AM ($USM) 2017 - 2028
Exhibit 3-23: Thermoplastic Powder Demand in Automotive AM (Kg) 2017 - 2028
Exhibit 3-24: Thermoplastic Powder Revenues in Automotive AM ($USM) 2017 - 2028
Exhibit 3-25: Regional Distribution for AM Materials Demand in Automotive AM
Exhibit 3-26: Regional Distribution for AM Materials Revenues in Automotive AM
Exhibit 3-27: Primary Software Known to Be Used in the Additive Manufacturing Process for Automotive Production
Exhibit 3-28: Revenues Associated with AM Software (excluding CAD) in the Automotive Segment
Exhibit 3-29: Year-on-Year Growth and Growth Trend for AM Software in Automotive
Exhibit 3-30: Regional Distribution of AM Software Revenues in Automotive AM
Exhibit 4-1: Total Metal and Polymer Units and Overall YoY Growth Rate for AM Parts Demand in the Automotive Segment 2017 - 2028
Exhibit 4-2: Total Revenues Generated by Metal and Polymer AM in Outsourcing and Growth Trends 2017 - 2028
Exhibit 4-3: Total Revenues Generated by AM Services for Metal Parts 2017 - 2028
Exhibit 4-4: Total Units Produced by AM Services and External Suppliers for Metal Parts 2017 - 2028
Exhibit 4-5: Revenues Generated by AM Service Bureaus and External Suppliers for Automotive by Polymer AM Part Type 2017 - 2028
Exhibit 4-6: Total Units Produced by AM Services and External Suppliers for Polymer Parts 2017 – 2028
Exhibit 4-7: Comparison Between Types of Metal Units Produced by External AM Services and Suppliers 2017 vs 2028
Exhibit 4-8: Types of Metal Units Produced by External AM Services and Suppliers at the End of the Forecast Period (2028)
Exhibit 4-9: Comparison Between Types of Polymer Units Produced by External AM Services and Suppliers 2017 vs. 2028
Exhibit 4-10: Types of Polymer Units Produced by External AM Services and Suppliers at the End of the Forecast Period (2028)
Exhibit 4-11: Summary of Auto Industry Stakeholders and 3D Printing Penetration Analysis
Exhibit 4-12: Hierarchy of 3D Printed Automotive Prototype Parts
Exhibit 4-13: Total Metal Prototyping Revenues in Automotive AM 2017 - 2028
Exhibit 4-14: Total Polymer Prototyping Revenues in Automotive AM 2017 – 2028
Exhibit 4-15: Tooling Applications for Different 3D Printing Processes
Exhibit 4-16: Total Revenues for Metal Tools, Jigs and Fixtures in Automotive AM 2017 - 2028
Exhibit 4-17: Total Revenues for Polymer Tools, Jigs and Fixtures in Automotive AM 2017 - 2028
Exhibit 4-18: Total Revenues from Metal Final Parts in Automotive AM
Exhibit 4-19: Total Revenues from Metal Final Parts in Automotive AM
Exhibit 4-20: Total Revenues from Metal Final Parts in Automotive AM by Specific Part Type
Exhibit 4-21: Total Revenues from Polymer Final Parts in Automotive AM by Specific Part Type
Exhibit 4-22: Cumulative Revenues Generated by AM Final Parts Production in Metal and Polymers (including composites) for the Automotive sector


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