Automotive Prototyping
Automotive industry is most demanding. First-time-right and time-to-market are extremely critical. Over 23+ years, 3DPD has worked with every automotive company across all aspects — plastic as well as metal; interior, exterior, or under-the-hood.
Case Studies
Automotive Projects
From single prototypes to production-ready validation — delivered on time, every time.
Transmission Housing Assembly
Critical component for transferring torque from engine to wheels. Manufactured via Investment Vacuum Casting with Aluminium LM25-T6. CNC post-machining achieved tolerances under 10 microns. 3 quantities produced.
Challenges
- Achieve sub-10-micron CNC tolerances on cast aluminium
- Maintain structural integrity under torque loads
- Investment casting quality from rapid prototyping process
Processes Used
Result
3 fully functional housings with injection-moulding-equivalent precision.
IP Dashboard Assembly
Instrument panel assembly comprising 16 child parts. Manufactured using SLA for master patterns and CNC Block Machining in ABS. Finished and painted to OEM presentation quality.
Challenges
- 16 separate child parts requiring perfect fit and alignment
- Presentation-grade surface finish and paint quality
- Tight turnaround for design review milestone
Processes Used
Result
Complete dashboard assembly delivered for executive design review.
Door Handle
Functional door handle prototype required to pass 30,000 cycle endurance tests. SLA masters used to create silicone moulds, then 50 sets produced via vacuum casting with painting and finishing.
Challenges
- Must survive 30,000 open-close cycles
- 50 sets needed for testing across multiple vehicles
- Paint and texture matching OEM specifications
Processes Used
Result
All 50 sets passed 30,000-cycle endurance testing.
HVAC Unit
Heating, ventilation, and air conditioning unit with critical 1.8mm wall thickness. SLA masters with silicone moulds, then 15 sets vacuum cast for functional airflow testing.
Challenges
- Maintain uniform 1.8mm wall thickness throughout
- Functional airflow testing requiring accurate internal geometry
- Match computational fluid dynamics (CFD) predictions
Processes Used
Result
Test results matched 90% of CFD simulation predictions.
Split AC Unit
Air conditioning enclosure prototyping using SLS. Early prototyping via Selective Laser Sintering identified 8 design errors before tooling investment. Follow-up vacuum casting validated CFD performance.
Challenges
- Identify design errors before committing to tooling
- Validate CFD simulation results with physical testing
- Tight project timeline with OEM launch date
Processes Used
Result
Found 8 design errors. Vacuum cast matched 93% of CFD. Saved 4 weeks of potential delay.
Portfolio
More Automotive Work
A selection of automotive components and assemblies from our portfolio.
Front Bumper Assembly
Full-scale exterior prototype
Clutch Housing
Metal investment casting prototype
HVAC Unit
Functional airflow testing model
Tail Lamp Assembly
Transparent optical prototype
Notable Automotive Clients
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From concept models to production-validation prototypes — we deliver automotive-grade quality with rapid turnaround.
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