The Best 3D Printing Materials Transforming the Automotive Industry

Lightweight. Durable. Cost-effective. These are the key demands in today’s automotive manufacturing—and modern 3D printing materials are meeting them head-on. As electric vehicles and sustainability take center stage, automakers are switching from traditional metals to high-performance polymers and advanced composites. The result? Up to 74% weight savings and 50% lower part costs.

Brands like Mercedes-Benz, Toyota, and Ford are already reaping the benefits. But they’re not alone—providers like zone3Dplus are helping companies worldwide access cutting-edge materials, fast turnaround, and affordable on-demand production.

Why 3D Printing Materials Matter in the Automotive World

3D printing isn’t just for prototyping anymore. It’s changing how cars are designed, built, and repaired.

Here’s why it matters:

  • Faster prototyping: Days instead of weeks.
  • Complex geometries: Lightweight designs that reduce fuel usage.
  • On-demand production: Fewer warehouses, less waste.
  • Eco-friendly options: Bio-based and recycled materials.

For instance, Mercedes-Benz produces over 100,000 prototype parts each year using 3D printing—and stores 40,000+ spare part files digitally.

zone3Dplus offers similar services, enabling automotive teams to upload CAD files, choose from a wide range of materials, and receive custom parts in days—not weeks.

Top 3D Printing Materials Driving Automotive Innovation

1. Engineering Plastics – For Prototypes and Lightweight Parts

  • PA6 / PA11: Tough and heat-resistant (up to 95°C). PA11, made from castor oil, is eco-friendly and ideal for engine covers, brackets, and housings.
  • TPU: Flexible and strong—great for gaskets, ducts, and vibration mounts. Shore 88A grade offers a perfect balance of toughness and elasticity.
  • PP (Polypropylene): Chemical-resistant, cost-efficient, and used for dashboards, fluid systems, and interior trim.

At zone3Dplus, clients regularly print these materials for early-stage testing and final-use components—especially when quick design changes are needed.

2. High-Performance Polymers – For Functional and Heat-Resistant Parts

  • PEEK & PEKK: Aerospace-grade strength and can handle over 250°C—ideal near engines and exhausts.
  • Somos Taurus: A rigid resin used by Toyota for intake prototypes. Withstands 95°C and offers high tensile strength (51MPa).

3. Metal Alloys – For Load-Bearing and High-Stress Components

  • Aluminum: Lightweight and strong. Mercedes cut part costs by 50% with aluminum SLM-printed brackets.
  • Stainless Steel: Durable and corrosion-resistant, perfect for drivetrain or mold components.
  • Titanium: Ultra-light, ultra-strong. Used for EV cooling systems and suspension parts.

The Mercedes Vision EQXX replaced 70 subframe parts with one sand-cast aluminum piece—designed using 3D printing.

At zone3Dplus, clients can choose from multiple metal printing options (SLM or DMLS) to create critical parts without the cost of tooling.

4. Composite Materials – Next-Level Strength and Weight Reduction

  • CF/PP (Carbon Fiber + Polypropylene): Five times stiffer than steel—ideal for body panels, bumpers, and structural reinforcements.
  • Nylon CF: Strong and wear-resistant. Replaces traditional parts like slide bearings and gear covers.

Toyota’s Hyper-F concept uses these materials for high-strength, lightweight parts made using pellet-fed 3D printers—something zone3Dplus is also exploring to scale large-format prints affordably.

Quick Material Comparison Table

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Real-World Results from Leading Automakers

  • Mercedes Trucks: Used 3D printing to eliminate tooling for metal engine mounts.
  • Toyota Racing: Used Somos resin for rapid aerodynamic testing—multiple prototypes in one day.
  • Ford Europe: Reduced tool production from 10 weeks to 10 days using desktop 3D printers.

zone3Dplus clients in the automotive sector have done the same—producing transparent headlight covers, tough car mod parts, and nylon-based airflow components faster than ever before.

What’s Next: Trends Driving the Future of Auto Manufacturing

  • Digital Spare Parts: Mercedes lets customers license digital files and print locally.
  • Pellet-Fed Printers: Used by Toyota and zone3Dplus for faster, recyclable production.
  • Massive Market Growth: Automotive 3D printing is forecast to hit $129 billion by 2026, largely driven by EV and lightweight part needs.

Final Thoughts

Choosing the best 3D printing material depends on your part’s role, heat exposure, and durability needs. For most auto makers:

  • Plastics work best for prototypes and interiors.
  • Metals shine in high-strength applications.
  • Composites offer unmatched strength-to-weight ratios.
  • Resins like Somos fill the gap between visual models and functional tests.

At zone3Dplus, we help automotive companies go from CAD to car-ready in record time. Whether you’re building EV parts, lightweight brackets, or functional jigs, we provide the material range, precision, and speed to drive innovation forward.

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