Deloitte Supplement - January 6, 2020 - D20

Industry 4.0 in automotive

vehicles. Second, AM can deliver more flexibility to

The time saved is also a critical benefit. Even if we're

make unique designs.

targeting low-volume production runs, we cannot
have a build process that takes too long. Therefore,

From a business standpoint, prototyping physical

reducing the time it takes to manufacture a part with

parts is very costly, so the more we can do to validate

faster printers and more efficient processes is a key

a component in the digital space, the more we can

objective. Also important is the "box size," or the part

control our costs. We obviously must maintain robust

density we can achieve within the usable printing

physical validation capabilities to ensure performance

volume, so that we are never printing just one part at

requirements are met, but there are huge benefits

a time.

from being able to do some of the work upfront using
digital tools.

The accuracy of the build process is the next benefit.
Every time we need to alter a component in a

In fact, we can simulate all input parameters for a

postprocess environment, it adds to the overall cost.

given component before we print it. In this way, we're

Getting the execution right in the initial build process

able to better set the conditions for success because

can reduce the number of postprocessing steps,

we may only have to print a small number of

thereby cost.

iterations to get it fully dialed in prior to production.
Finally, we must consider the materials used in AM.
There are opportunities to utilize both printed metals

Unlocking the potential benefits

and plastics for the parts that make up our vehicles
and the tools that produce the components. More

In terms of implementing AM solutions, there are

material development must be done to enable the full

four key considerations: cost, throughput,

suite of automotive-grade 3D printed materials that

postprocessing requirements, and material

our industry requires. For example, the 3D printing

availability. Additive cost models can change the

industry has developed exotic metal powders, such as

paradigm with the simple realization that you don't

titanium and nickel base alloys, for the aerospace and

have to first build a tool anymore; you can go straight

medical industries. The automotive industry does not

to building the part. The cost-benefit extends even

use many of these materials in production, so we need

further as unlike tools-that are typically built to

more development and focus on steel and aluminum

support a five-year vehicle life cycle plus additional

to meet our specific needs.

service part production-we can reuse the same
AM printer across multiple vehicle programs and

Bringing parts manufacturing
to the final assembly line

design generations.
As a manufacturer, it is a very compelling value
proposition to think that you can now amortize the

Parts production currently entails a complicated

cost of tooling over a much wider volume and longer

system of logistics connecting a multitude of tiered

period. Achieving this leverage model is an important

suppliers constantly shipping components back and

goal, as some industry estimates suggest that AM can

forth across the manufacturing ecosystem. AM could

increase the piece cost of making some parts versus

minimize waste and downtime in this process by

using traditional methods by a factor of 10 to 100.

printing more components on location at the final
vehicle assembly facility. While having an AM

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Deloitte Supplement - January 6, 2020

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