Via its Metal 3D Printing Centre in Ingolstadt, Audi uses the EOS M 400 system to produce 12 segments of four tools for hot forming, including body panels for models such as the Audi A4.

As the firm shifts more of its production from conventional manufacturing to additive manufacturing, Audi says it plans to produce its future electric vehicles using 3D printing.

According to Matthias Herker, technical project manager at the Audi Metal 3D Printing Centre, additive manufacturing allows Audi to continue to produce parts when traditional manufacturing methods “reach their limit”.

Herker says: “From initial qualification by EOS to internal further development and refinement of the entire process chain through to standardisation of a new production method, we are now reaping the fruits of years of development within Audi’s production organisation.”

Since the launch of the 3D Printing Centre in 2016, EOS has worked closely with Audi to provide technology, share knowledge, and give support.

With tools often measuring in at up to 5 x 3 meters and individual tool segments measuring up to 400mm in length and 120kg in weight, construction can take up to 20 days.

3D printing has become an established part of Audi’s production process

According to EOS, 3D printing makes it possible to produce “highly complex cooling channels” which in turn shortens cycle times.

Markus Glasser, senior vice president EMEA at EOS adds: “The latest examples show that 3D printing has become an established part of operating materials production at Audi.

“We’re especially proud that the tool segments made using additive manufacturing are created exclusively using an industrial 3D printer from EOS. Audi is a partner we can work with to continue to drive the use of additive manufacturing in automotive production – a key industry for us.”

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