Rapid manufacturing of automotive polymer series parts: A systematic review of processes, materials and challenges

Additive manufacturing (AM) is moving towards series manufacturing applications across a variety of industries. However, take-up for series production in the automotive industry is still slow and limited to very few materials. Therefore, this review assesses compatibility of polymer AM processes and materials and provides a method to check their formal applicability for automotive series part production. The proposed material and process selection method applies basic automotive requirements derived from the VDA 232-201 industry standard and an interior part case study. Materials and processes in AM are put into context via material selection charts and a process compatibility index. This graphical analysis enables first judgement about applicability and subsequent pre-selection of materials and processes. Insights may help users, equipment manufacturers and material developers in the fields of AM to match automotive requirements and reduce barriers for adoption of AM in series part manufacturing