Design and build a fully functional, all-electric, EV car using sustainable production methods.

The Challenge – Full-Scale Functional Prototyping

One of the challenges of transportation prototyping is building full-scale parts without the need to bond multiple pieces together. Industrial 3D printers allow large components to be printed in one piece. For instance, Massivit’s gel-based 3D printing technology uses UV light to cure large components on-the-fly while printing. This enables ultra-fast creation of full-scale components that can then be reiterated and quickly printed again within a few hours, as needed. Large car panels, train covers and truck grills alike can be produced with relative ease. The case study below explores how LSAM (large scale additive manufacturing) is serving faster design and development lead times as well as sleek new design possibilities.

The Players

Rafael Corazza Ronchetti, a former Lamborghini and Audi designer for Super Cars, is now a Professor of Industrial Design at SCAD (Savannah College of Art and Design). He teamed up with a SCAD crew of engineers to bring to life The Aether – an additively manufactured functional EV whose design is strongly influenced by the Ferrari 312 F1 and Porsche 917.

Ronchetti’s colleague, Owen Foster – SCAD Design Associate Chairperson, highlighted the fact that “Gen Z and Gen Alpha drivers are looking for something that will amplify their own unique journey through life.”

Solution – Fully 3D Printed EV Concept Car

The Aether – ‘God of the Upper Atmosphere’ – was manufactured with an entirely 3D-printed body. Custom Design Studio, Hatch Exhibits, partnered with the SCAD team to rapidly print the main car panels using a Massivit 5000 large-scale 3D printer. Based on Gel Dispensing Printing technology, this industrial-grade printer allows automotive design teams to produce any desired geometry based on CAD designs or 3D scans. Inspired by early Ferrari and Porsche models, the Aether is an elegant, convertible EV, designed to attract a younger demographic. It is a fully-electric battery-operated vehicle offering an AI dashboard to enhance the driver experience by matching music to specific driving patterns. The car has transparent internal paneling for tech-savvy enthusiasts.

Less is More – Sustainability Drives Production

Sustainability was a major driving factor for the SCAD team on The Aether. Their decision to create the full-size mockup with industrial 3D printers is largely based on the sustainability factor. Additive manufacturing by nature only uses the minimum required material, as opposed to traditional milling, machining, or clay methods which generate huge amounts of material waste. Moreover, 3D printers enable OEM’s and service bureaus to bring all production inhouse – meaning reduced transportation needs and reduced overall carbon footprint. Another major benefit for automotive manufacturers is centralizing the design and development inhouse in order to safeguard sensitive design IP.

Less of a Puzzle

The ability to print single big panels overcomes the old-age car manufacturing issue of having to bond multiple smaller parts together to make a 1:1 component. This enables greater overall design accuracy.

Elegance & Speed

The Aether was showcased in all its glory at the 2024 Formula 1 U.S. Grand Prix in Austin, Texas. Meeting the production deadline on time, not only did this masterpiece attract attention from car designers and aficionados, but it well-and-truly fulfilled the goal to build a fully functional, all-electric, car using sustainable methods.

Curious to discover large-scale 3D printing benefits? Reach out to us here.

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The Massivit 5000 Series, known for its swift additive manufacturing capabilities, played a crucial role in the rapid production of the dragon. Leveraging Massivit’s Gel Dispensing Printing (GDP) technology, the printer enabled Art & Soul to print a giant, complex Chinese dragon at an astonishing speed –as Massivit’s technology is 30 times faster than traditional Additive Manufacturing technologies.

The installation will be featured in 2 additional travel retail activations for Heinemann’s pre-golden week and golden week in 2024 at Sydney Airport.

Heinemann Australia’s Managing Director, George Tsoukalas, reported a dramatic increase in consumer traffic resulting from the stunning display: “It’s always a pleasure to work with Art & Soul Creations, the team’s expertise and passion for spatial design and experiential retail activations make for quick turnarounds with quality craftsmanship. This year’s 3D-printed Lunar New Year Dragon was a showstopper and exceeded our expectations. We saw a significant increase in foot traffic, and their signage solutions both enhanced our brand visibility and breathed life and theatre into the popup space as travellers would stop for photos and leave with a lasting impression of their time in Sydney.”

The dragon, a symbol of strength and good fortune in Chinese culture was meticulously crafted by Art & Soul’s skilled team. After printing the dragon, the artisans focused on refining its surface through sanding and smoothing, culminating in an even application of regal gold spray paint. The final masterpiece is now the centerpiece of Sydney Airport’s Lunar New Year display, serving as a testament to Art & Soul’s expertise in spatial design, fabrication, and installation. This project showcased the Massivit 5000’s capabilities in high-speed 3D printing and Art & Soul Creations’ commitment to delivering intricate 3D displays for special occasions.

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As yacht design advances to incorporate increasingly intricate shapes, the traditional methods of constructing custom Jacuzzi areas for superyacht sundecks face significant challenges—the evolving complexity in design demands close attention to dimensional, shape, assembly, and production control.

Challenges Presented By Standard Method

Woltz Nautic Italy experienced many challenges when building a custom Jacuzzi area for a luxury yacht. While employing the conventional approach, the shipyard employed a metal substructure for the Jacuzzi area. The standard method led to issues such as losing dimensional control during the fairing, leveling, and painting processes.

The traditional method involved a cumbersome sequence of steps, including 3D scanning, leveling, fairing, painting, additional scanning, and manufacturing of custom parts. This multi-step process necessitated several onboard visits and frequent adaptations, often resulting in the final parts differing from the original design due to required modifications. Furthermore, the manual craftsmanship involved in the standard method and the need for operator skills made the process time-consuming and costly for both the supplier and shipyard and lacked material-saving measures.

Primarily, the challenges with the standard method include the need for multiple scans and adaptations, reliance on manual craftsmanship, time inefficiency, cost-inefficiency, and a lack of precise dimensional control, which ultimately prompted Woltz Nautic Italy to seek alternative solutions.

In addressing the challenges inherent in the standard process, Woltz Nautic Italy identified Massivit’s Additive Manufacturing (AM) technology as an ideal alternative for superyacht sundeck design.

Design Freedom and Optimization

Massivit’s additive manufacturing technology tackles design constraints by enabling the engineering of intricate structures optimized for performance and functionality. This alleviates boat manufacturers from traditional limitations, allowing for the direct translation of once-challenging designs into directly-printed, high-performance components.

The speed of Massivit’s technology directly addresses time inefficiencies in the production cycle. It expedites prototype production, streamlining the entire product development process. This acceleration enables engineers to test and iterate designs efficiently, resulting in streamlined processes, reduced labor costs, and a quicker time-to-market.

Material Efficiency and Sustainability

Massivit’s technology counteracts waste generated by traditional subtracting methods, minimizing waste through the additive process. The technology offers a comprehensive range of material options, allowing Woltz Nautic Italy to create water-resistant/hydrophobic parts. The strategic selection of materials based on specific properties is both an ecological benefit and a practical approach to optimizing performance and sustainability.

Customization and Customer-Centric Approach

The customization capabilities of Massivit’s AM technology offer a customer-centric solution to the adaptability challenges highlighted in the problem statement. The ability to produce customized and personalized parts diversifies Woltz Nautic Italy’s offerings and enhances customer engagement. The technology’s support for large-scale customization reflects a market-aligned strategy, providing flexibility in responding to diverse client preferences.

Efficiency in Sundeck Jacuzzi Area Production with Massivit 5000

Applying Massivit’s AM technology to craft the Jacuzzi area on the sundeck presents a strategic solution, addressing the challenges faced by Woltz Nautic Italy during the construction of custom Jacuzzi areas for luxury yachts. The Massivit 5000, in particular, offers a range of key benefits that have significantly influenced Woltz Nautic Italy’s decision to purchase the Massivit 5000:

• Acrylic-Based Material: Utilizing an acrylic-based material, the Massivit 5000 ensures lightweight components with enhanced durability.
• Lightweight and Strong Layer Adhesion: The Massivit 5000’s 3D-printed components are not only inherently lightweight, crucial in yacht design, but also boast strong layer adhesion, ensuring structural integrity.
• Speed of Production: Massivit’s technology excels in speed, completing the engineering and 3D-printed part production in less than 200 hours. This rapid prototyping capability streamlines the entire production cycle, reducing time inefficiencies and allowing for quick iterations of designs.
• Process Efficiency (No Milling Needed): Unlike the traditional method that involves milling before applying fiber or coating, Massivit’s technology eliminates this step. The direct 3D printing of geometry from CAD designs and wood finishing implemented onto the 3D printed part exemplifies a manufacturing process engineered directly from the design.

These benefits collectively contribute to a streamlined production process, resulting in lightweight, high-performance components for the Jacuzzi area. The estimated production time of approximately 200 machine hours, including finishing, underscores the efficiency of Massivit’s technology. This quick installation, control over dimensional accuracy, and factory assembly and testing options collectively reduce cross-building time and eliminate the need for additional onboard time, providing a tangible solution to operational inefficiencies.

In summary, Massivit’s additive manufacturing technology provides a faster and more efficient solution, aligning seamlessly with Woltz Nautic Italy’s objectives in overcoming challenges in superyacht sundeck design.

Comparison with Standard Method

Massivit’s additive manufacturing technology transforms boat manufacturing, diverging significantly from the traditional approach. The standard method necessitates a minimum of four on-site visits involving scans, finishing, and installations, whereas additive manufacturing potentially requires only one visit, reducing disruptions to the working environment.

Regarding production time, the standard method spans weeks or months, considering intricate processes like engineering, scans, and retro-engineering. In contrast, additive manufacturing completes engineering and 3D-printed part production in less than 200 hours, accelerating the timeline. Assembly in the standard method demands on-site work, occupying the site with a team, while additive manufacturing allows for assembly at the factory, eliminating cross-building time on-site. Installation in the standard method requires standard time, finishing, and adaptation. In contrast, additive manufacturing potentially achieves the entire process in just one working day, with all components pre-tested at the factory. Massivit’s additive manufacturing enhances precision and efficiency, significantly streamlines on-site disruptions, and accelerates the production timeline compared to the standard method.

The paramount advantages presented to Woltz Nautic Italy with Massivit’s additive manufacturing technology include the remarkable speed and ease of the large-scale 3d printing technology, leading to a substantial reduction in labor time and costs. Skilled labor, often scarce and expensive, becomes more efficiently allocated as Massivit’s technology streamlines the production process. This efficiency saves labor and allows employees to engage in other projects concurrently.

Furthermore, Massivit’s 3D printing technology enables Woltz Nautic Italy with enhanced customization capabilities, allowing Woltz Nautic Italy to leverage directly printed, customized solutions that meet the unique preferences of their clients. By coupling cost savings with labor efficiency, Woltz Nautic Italy positions itself as an industry leader with a competitive edge in the dynamic market of innovative yacht design.  

In summary, Massivit’s Additive Manufacturing technology has proven to be a transformative force, enabling Woltz Nautic Italy  to pursue new heights in efficiency, cost-effectiveness, and market distinction. The unparalleled benefits of speed, labor savings, enhanced customization, and a competitive edge are available through the adoption of Massivit’s technology. As Woltz Nautic Italy continues to pioneer innovative solutions in yacht design, the company remains steadfast in its commitment to continued innovation, further solidifying its position as an industry leader at the forefront of technological advancement.

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This is one of the industry’s greatest challenges that today can be easily solved with the latest 3D printing technologies. One example is this exceptional sculpture produced by Massivit’s Mexico-based customer, Laboratorio Mexicano de Imágenes. The company used Massivit’s large-scale 3D printer to create the impressive King Tut sculpture.

Serving as the centerpiece for the captivating showcase by Mexican production company Bidur Sa De Cv, this massive 3D-printed sculpture was crafted in just sixty-two hours, utilizing 40kg of printing material. The King Tut statue highlights the impressive capabilities of Massivit’s industrial 3D printers, literally bringing history to life for global audiences. The giant Tutankhamun is touring various cities across the USA, and the exhibition still offers visitors a distinctive and enthralling experience.

As audiences delve into Tutankhamun’s intriguing journey at the museum, this exhibition not only animates ancient history but also exemplifies the seamless integration of additive technology and culture. Massivit’s cutting-edge large-format 3D printing takes center stage in presenting the 3D-printed Tutankhamun—a truly fantastic display that bridges the past with the present.

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In 2022, the team took advantage of latest large-scale additive manufacturing technologies from Massivit. The team rocked up at: • Formula Student Germany (FSG) • Formula Student Croatia (FSAA) Joining the global snowballing trend towards Electric Vehicles, the Ben Gurion University team entered the EV category, taking advantage of a Massivit 1800 large-scale 3D printer to print the nose of the car with Massivit customer Elidar.

The team used a Massivit 10000 additive manufacturing system to produce 3D printed wash away mandrels for the carbon fiber wings.

Unlike combustion requirements, the EV category requires:

• Extreme acceleration (0-200kim/h)

• High inertia

• Lightweight components The BGU team participated in performance and endurance tests including Static, Dynamic, and Acceleration tests.

Massivit’s water-breakable printing material, DIM WB, enabled the team to produce complex geometries and combine the benefits of AM tooling with lightweight composites for an overall win.

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Watch Neil Patrick Harris’ reaction as the 3D Printing Nerd reveals a special surprise
for his home in the Hamptons…

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Production of Aerospace parts often requires multiple tooling processes, bonding, as well as finishing applications. The initial additive manufactured part needed to be produced with high precision to achieve the final desired tool. ACS Hybrid Inc. used their Massivit 1800 Pro in collaboration with 3D Composites for this proof of concept. ACS Hybrid Inc. are experts in producing large molds for thermoforming for the Aerospace industry. 3D Composites have over 30 years’ experience designing and producing parts for the Aerospace industry using additive manufacturing.

Solution:

To minimize post processing time, the mold was 3D printed on the Massivit 3D printer’s highest resolution and took just 16 hours to print.

Results:

The additive manufactured mold withstood 45 pulls of 0.063” Kydex (ABS) sheets without showing any major signs of deterioration. Additionally, the mold was produced with less parts, less waste, and at a lower cost than producing it with traditional subtractive methods.

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Other Adaequo team members confirm “The speed of the Massivit 1800 is unbelievable! We can now set up a printing file in minutes instead of configuring CNC technology for hours and hours.” The team is proud of their latest dynamic Point of Purchase displays “in motion” that instantly generate selfies and help brands go viral.

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Thankfully, Deko 3D has a Massivit 1800 large format 3D printer in their arsenal. This powerful machine was put to work to create the first ever completely 3D-printed handball player. In only 11 hours, it produced an incredible replica that stands at a height of 1.80 meters and weighs 34kg.

Club president Alain Poncet marveled at how good the 3D-printed player looked in his team’s uniform. “He is a beautiful defender – I’m now ready to create a whole team with various heights!”

Poncet instantly understood the magnitude of this new asset and how it helps build hype around the team. Fans could interact with the handball player and take selfies, embracing their connection with the team, and the sport as a whole.

The power of large format 3D printing to help brands reach their audience is unparalleled. Having recognized the qualitative difference it can make, print shops around the world are rushing to embrace this incredible technology.

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This time around the focus point was an ornate 3D eagle belt buckle; an oversized replica of Armani’s belt accessories in their current line. 3D printed in just 29 hours and measuring 6.9ft x 3.9ft (2.1m x 1.2m), the oversized eagle buckle was finished with metallic silver paint, bevelled plexiglass, and glitter inserts.

A second version was 3D printed in only 15 hours and measured 6ft x 4.3ft (1.8m x 1.3m), integrated in a billboard of the same campaign. Here, the finish was in chrome silver metallic paint and matte silver.

The 3D capabilities that Colorzenith brings to the table, courtesy of their Massivit large format 3D printer, have enabled blossoming relationships with seminal brands such as Armani. They treasure their long standing relationship with Armani because of its vision and creative drive to develop fresh, crowd-stopping campaigns leveraging new technologies and concepts. The 3D touches in this campaign compel people to take a moment to admire them. The attention to detail was fundamental in reflecting the Armani brand.

For print shops such as Colorzenith, having a large format 3D printing solution in-house gives them an advantage to not only get the job, but to create repeat business. It’s one more reason why print service providers are turning to large format 3D printing to support and expand their business model.

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