3D printing has been an integral part of Daimler's operations for over 25 years, with extensive experience in all conventional additive manufacturing techniques. At the Sindelfingen and Untertürkheim plants alone, approximately 100,000 components have been produced using additive methods and delivered to development teams or production lines. The current focus is on creating models, visual aids, prototypes, and tools, as 3D printing offers significant potential in the prototyping phase. We are continuously expanding this area to improve efficiency and innovation.
In passenger car production, 3D printing is used to develop customized tools and equipment, such as adjustment and assembly aids, which help optimize the manufacturing process. Compared to traditionally manufactured parts, these 3D-printed solutions can reduce both cost and weight, leading to better ergonomics and working conditions on the factory floor.
In the spare parts business, 3D printing is particularly useful for meeting special customer requests or for classic vehicles where traditional manufacturing no longer supports tooling. Since 2016, the company has been using additive manufacturing to produce plastic parts, especially in commercial vehicle divisions like Unimog. There are now 30 approved Mercedes-Benz truck spare parts that can be produced using 3D printers. In the bus sector, additive manufacturing is being used to fulfill a wide range of custom orders, showing strong growth potential.
However, large-scale production with 3D printing still faces challenges. The limited capacity of each printer restricts the number of parts that can be made at once. Additionally, the layer-by-layer construction process often takes several hours or even days, making it less efficient for mass production. The materials used, such as powders, are also relatively expensive.
Despite these limitations, the future of additive manufacturing looks promising. With continuous process improvements and increased automation, 3D printing could eventually overcome these barriers and play a larger role in large-scale production. As technology advances, we expect to see more applications of additive manufacturing across all areas of Daimler’s operations.
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