ForgeLabs Advanced ManufacturingForge Labs

Automotive 3D Printing for Production Parts, Tooling and Prototypes

Line tooling, cab and HVAC parts, under-hood and metal components, and service parts for vehicle makers and their suppliers, made in North America and reordered lot after lot.

  • Low-volume and bridge production without hard tooling.
  • Nylon, carbon-fibre nylon, ULTEM and metal for heat and fluids.
  • Next day shipping anywhere in the US and Canada.
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Automotive 3D Printing Solutions
Automotive Overview

From plant-floor tooling to service parts

Vehicle makers and their suppliers use Forge Labs where tooling would be slow or never pay back: assembly nests and protective tray inserts for hairpin stator production lines, HVAC ducts and control enclosures for vehicle cabs, finned aluminium housings, injector adapters and pump mounts, headlight surrounds and clear light diffusers, and service parts reordered for fleets that are no longer in production. We make them in North America with MJF, SLS, FDM, SLA, PolyJet and DMLS, quote online from 2 business days with 24-hour turnaround on request, and ship next day anywhere in the US and Canada.

Where additive creates leverage

Built for faster automotive decisions

Forge Labs helps teams move from design validation to production-ready parts without waiting on tooling lead times. Consolidated assemblies, lighter parts, and faster revisions give engineering teams more control over schedule, cost, and performance.

Key manufacturing benefits

  • Run low-volume and bridge production without paying for hard tooling.
  • Reorder service parts from your order history instead of warehousing them.
  • Consolidate brackets, duct paths and mounting features into single parts.
  • Print fluid-contact and under-hood parts in PA12, ULTEM 1010 and carbon-fibre nylon.
  • Replace cast aluminium housings and brackets with DMLS AlSi10Mg.
  • Validate fit quickly, with 24-hour turnaround on request.
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Automotive Manufacturing Process 1
Automotive Manufacturing Process 2
Automotive Manufacturing Process 3
Automotive Manufacturing Process 4
Quality and compliance

Production controls for automotive parts

Automotive customers send drawings, tolerance callouts and repeat orders. We work to them with documented inspection, supplier material data and lot tracking from first article to the latest reorder.

ISO 9001-aligned quality processes
Production follows ISO 9001-aligned processes with dimensional inspection against your drawing and tolerance callouts.
First article and production sampling
Add first article inspection or production sampling to an order where offered for the material, before and during repeat production.
Supplier material data
Fluid, heat, UV and flammability data from Stratasys, HP, EOS and 3D Systems for each material, and material certifications on request.
Interior flammability data
MJF PA12 passes FMVSS 302 and CMVSS 302 on our HP 5200 platform, and ULTEM 9085 has been tested to UN ECE Regulation 118 for bus interiors. Specific flammability requirements are run on the matching platform.
Repeat lots and service parts
Part files stay in your parts library; lots are reordered from your order history with the same file and settings.
Ordering and order status
Upload STEP, STL, OBJ or IGES files with drawings, track order status from upload to delivery, and reorder in a few clicks.
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Manufacturing Capabilities

3D Printed Automotive Parts and Fixtures

The automotive parts we make most often, with the processes, materials and material data behind each.

SLS nylon assembly nest holding a stator on an electric motor line
SLS nylon assembly nest holding a stator on an electric motor line

Line-side tooling

Production Tooling & Assembly Fixtures

SLS and FDM make assembly nests, fixtures, drill guides, soft jaws and protective tray inserts for vehicle and electric motor production lines, including 500 flexible TPU inserts in one order. PAHT-CF carbon-fibre nylon makes stiff, light fixtures with a 170 °C heat deflection temperature and resistance to most oils and greases, and the large FDM envelope takes vehicle-scale fixtures in one piece in ULTEM 1010.

Typical parts
Assembly nests, fixtures, drill guides, soft jaws, tray inserts
Key properties
FDM builds to 914 × 609 × 914 mm; ±0.25 mm or ±0.3%, whichever is greater
Material data
PAHT-CF: 170 °C HDT at 1.8 MPa, resists most oils and greases
Materials
Nylon PA12 (SLS)PAHT-CF Carbon Fiber Nylon (FDM)ULTEM 1010 (FDM)
Black 3D printed HVAC duct fitted behind a vehicle instrument panel
Black 3D printed HVAC duct fitted behind a vehicle instrument panel

Cabs, ducts and enclosures

Cab, HVAC & Interior Parts

MJF and SLS produce control enclosures, console frames, holders and brackets for vehicle cabs, and SLA builds HVAC ducts to vendor drawings in black resin, all reordered as vehicles are built. HP's MJF PA12 has passed FMVSS 302, identical to Canada's CMVSS 302, with a 0 mm/min burn rate on the Jet Fusion 5200 platform we run, and Stratasys has tested ULTEM 9085 to UN ECE Regulation 118, the bus-interior fire standard.

Typical parts
HVAC ducts, control enclosures, console frames, dashboard panels
Key properties
Parts up to 400 mm in one piece (SLS); SLA ducts to drawing
Material data
MJF PA12: FMVSS 302 / CMVSS 302, 0 mm/min burn rate
Materials
HP High Reusability PA12 (MJF)Nylon PA12 (SLS)Accura 25 (SLA)ULTEM 9085 (FDM)
DMLS aluminium finned housing on an electric drive unit
DMLS aluminium finned housing on an electric drive unit

Powertrain, fluids and heat

Under-Hood & Metal Components

PA12 is our default for fluid-contact parts: HP immersed MJF PA12 in motor oil, gear oil, ATF, grease, DOT 3 brake fluid and glycol coolant for four to six weeks at 60 °C with no chemical attack or stress cracking. ULTEM 1010 adds heat and is rated excellent against fuels and coolant. DMLS makes finned aluminium housings, injector adapters and brackets in AlSi10Mg, which EOS builds to about 99.85% density with as-built properties comparable to T6 cast aluminium, so it replaces cast parts directly.

Typical parts
Finned housings, injector adapters, pump mounts, ducts, reservoirs
Key properties
DMLS ±0.3% (min ±0.3 mm); heat treatment, HIP and machining available
Material data
MJF PA12 resists oils, ATF, DOT 3 brake fluid and coolant at 60 °C
Materials
HP High Reusability PA12 (MJF)ULTEM 1010 (FDM)Aluminum AlSi10Mg (DMLS)Titanium Ti-6Al-4V (DMLS)
3D printed replacement trim being fitted inside a transit bus
3D printed replacement trim being fitted inside a transit bus

Repeat lots and service parts

Low-Volume Production & Service Parts

Parts that never justified a mould are printed from the same file on every order: one small locating frame has been reordered in batches from the same file, and a transit fleet reorders trim for buses that are no longer in production. Part files stay in your parts library, lots are reordered from your order history, and order status is tracked from upload to delivery, with no minimum order or stored inventory.

Typical parts
Service and spare parts, trim, brackets, bezels, low-volume components
Key properties
No minimum order; repeat lots from saved files
Material data
HP PA12 and ASA, with material certifications on request
Materials
HP High Reusability PA12 (MJF)Nylon PA12 (SLS)ASA (FDM)
Black nylon headlight surround being fitted to a custom vehicle
Black nylon headlight surround being fitted to a custom vehicle

Exterior and lighting

Exterior, Lighting & Custom Vehicle Parts

Headlight surrounds, sensor covers, emblems and wheel covers for custom builds, autonomous vehicles and low-volume production. For sun-exposed parts we print ASA, which Stratasys weathered for 1,000 hours with almost no loss of strength; PA12 goes outside painted or coated. Clear light diffusers and lens prototypes are printed in Accura ClearVue, and DMLS 316L makes stainless emblems and trim.

Typical parts
Headlight surrounds, sensor covers, light diffusers, emblems
Key properties
Painted, dyed or as-printed finishes; parts up to 480 mm long (FDM)
Material data
ASA: ~3% strength change after 1,000 h UV; ClearVue 87.2% transmittance
Materials
ASA (FDM)Nylon PA12 (SLS)Accura ClearVue (SLA)Stainless Steel 316L (DMLS)
Boxed 3D printed automotive parts packed for next day shipping
Boxed 3D printed automotive parts packed for next day shipping

North American supply

North American Manufacturing

Parts are made in North America and ship next day anywhere in the US and Canada, so vehicle manufacturers avoid overseas freight, long customs holds and minimum order quantities. Stored part files are printed when they are needed, which keeps lines and fleets running through supply disruptions without holding stock.

Typical parts
Production, tooling and service parts for US and Canadian vehicles
Key properties
Next day shipping across the US and Canada; 24-hour turnaround on request
Material data
Material lots tracked on every order and reorder
Materials
HP High Reusability PA12 (MJF)Nylon PA12 (SLS)FDM
SLS nylon dashboard panel prototype held up for a fit check
SLS nylon dashboard panel prototype held up for a fit check

Fit checks and validation

Prototypes & Fit Checks

SLA and SLS build fit-check and validation prototypes, from dashboard panels and housings to body panels up to 1.5 metres long, with 24-hour turnaround on request. Accura ClearVue and VeroClear make clear lens and light-pipe prototypes, and PolyJet Agilus30 makes soft-touch grips, seals and overmould prototypes.

Typical parts
Dashboard panels, housings, body panels, lens prototypes, soft-touch parts
Key properties
Up to 1500 × 750 × 550 mm; SLA ±0.25% (min ±0.25 mm); SLS ±0.3% (min ±0.3 mm)
Material data
Accura ClearVue 87.2% luminous transmittance; Agilus30 Shore A 30
Materials
Accura 25 (SLA)Nylon PA12 (SLS)Accura ClearVue (SLA)Agilus30 (PolyJet)
Case Studies

Automotive Manufacturing Outcomes

Cab parts matched to three processes, hairpin stator line tooling and a part reordered from one file without tooling.

3D Printed Cab Parts: HVAC Ducts, Enclosures and Dashboard Panels

Case study

3D Printed Cab Parts: HVAC Ducts, Enclosures and Dashboard Panels

Large SLS nylon enclosures, a dashboard panel and separate duct orders show how geometry, finish and operating requirements guide the process. The examples connect build planning with practical repeat orders.

Key outcomes

  • Repeat production without mould tooling
  • Enclosures up to about 400 mm in one piece
  • SLA and SLS duct examples
  • Dashboard panel: order to dispatch in eight business days
Read the cab parts case studies
Hairpin Stator Assembly Nests in SLS PA12: Slot Fit, Tolerance and Dyeing

Case study

Hairpin Stator Assembly Nests in SLS PA12: Slot Fit, Tolerance and Dyeing

Slotted hairpin stator assembly nests used SLS nylon dyed black, while flexible snap-in tray inserts used TPU. Printing produced the repeated slot geometry and non-marring contact surfaces without machining each feature.

Key outcomes

  • 500 TPU tray inserts in one order
  • SLS nylon nests in the 250 mm class
  • Infill tuned for the flexible inserts
  • Delivered ahead of the line's need date
Read the assembly nest case study
Locating Frame Reordered in SLS PA12 Without Tooling

Case study

Locating Frame Reordered in SLS PA12 Without Tooling

This small SLS nylon locating frame is reordered from one unchanged file. Batch sizes follow demand, with no injection mould or minimum order quantity.

Key outcomes

  • Repeat orders from one unchanged file
  • Median 3 business days from order to shipment
  • No mould or minimum order quantity
  • Every dated order shipped early
Read the repeat production case study
Manufacturing Technologies

3D Printing Technologies for Automotive

Evaluate each process by geometry freedom, material options, and throughput so you can pick the right path from prototype to production.

Not sure which process fits? Our application engineers map your requirements to the right technology, material and finishing workflow before you commit to a build.

Chat with usCompare all technologies
Material Library

Materials for Automotive Parts

Engineering nylons, carbon-fibre nylon, ULTEM, UV-stable ASA, clear resin and metals chosen for heat, fluids, sunlight and weight. Compare full properties on each material page.

Explore the complete material matrix. Compare certifications, mechanical properties and application fit across the full portfolio before locking your production material stack.

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Ready to Manufacture Your Automotive Parts?

Upload your CAD files for an instant quote or speak with our application engineers about your specific requirements.

  • Instant pricing with automated manufacturability analysis
  • Production workflows built for repeatable quality
  • Engineering support from prototype to production
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STEP, STL, OBJ, 3MF and IGES supported

Manufacturing technologies
6
Engineering materials
50+
Part quantities
1-500+