Opel reduces assembly tool production costs by up to 90% with Stratasys 3D printing.

Sun roof assembly tool 3D printed by Opel with its Stratasys FDM 3D Printers.

Opel, Europe’s third-largest automotive manufacturer, is slashing manufacturing tool production costs by up to 90% using its Stratasys 3D Printers. Opel also creates 3D printing assembly tools in less than 24 hours.

With efficient production crucial to its success, Opel’s International Technical Development Center is 3D printing a range of manufacturing and assembly tools to advance the production of its iconic ‘Adam’ hatchback car. These assembly tools are used to precisely attach different components to the car, such as the rocker molding and roof spoilers; align the iconic ‘Adam’ lettering on the rear-side window, and assemble the glass and retractable roofs.

With Stratasys 3D printing, any design changes to the manufacturing tools are easily accommodated in a matter of hours, eliminating costly iterations further along the production process.

“Besides the cut in tool production time and considerable cost reductions, customized tools are a third important benefit achieved with 3D printing. We are now able to produce more complex shapes than we could via conventional manufacturing. This crucially allows us to adapt the tool to the worker and the specific car,” says Sascha Holl, Virtual Simulation Engineer – Tool Design at Opel.

Because Opel 3D prints its manufacturing tools, the company involves its assembly-line workers in the design process to improve efficiency. This allows operators to evaluate concepts, using their experience to highlight any potential issues before committing to the production of the final assembly tool for each specific car component. With Stratasys 3D printing, any required design changes to the Opel manufacturing tools are easily accommodated in a matter of hours, eliminating costly iterations further along the production process.

Opel’s Stratasys 3D printed assembly tools are used to align the iconic ‘Adam’ lettering on the car’s rear-side window.

“Cases like Opel emphasize the massive impact that low risk, high-reward 3D printed parts – such as manufacturing tools – can have on production efficiency,” says Andy Middleton, President, Stratasys, EMEA. “The capability to produce such items on-demand at a reduced cost can significantly accelerate time-to-production and give businesses that competitive edge. Combine that with the ability to customize tools efficiently, as well as create complex geometries, and you can see why Opel is indicative of the way in which additive manufacturing is transforming our customer’s production operations.”

To learn more about how Opel is using Stratasys 3D printed manufacturing tools to enhance the production line, watch this video.