Subaru Corporation, the Japanese automaker renowned for its boxer engines and all-wheel-drive vehicles, has adopted HP Inc.‘s Jet Fusion 3D printing technology to produce parts for its SUBARU LEGACY OUTBACK BOOSTGEAR PACKAGE concept car. Unveiled at the Tokyo Auto Salon 2024, this collaboration with HP Japan and DMM.make 3D Print—a division of the Japanese internet conglomerate DMM.com—explores new possibilities in automotive design and manufacturing.
Developing unique components for concept cars often involves high costs and lengthy processes due to the need for specialized molds. These limitations restrict design flexibility and make it difficult to produce customized, low-volume parts efficiently. By adopting HP’s MJF technology with the Jet Fusion 4200 and 5420W 3D printers, Subaru eliminated the need for molds, enabling rapid production of uniquely shaped parts within tight deadlines. The use of HP 3D High Reusability PA 12, a nylon material known for heat and weather resistance, provided the necessary structural strength while supporting environmental sustainability through an 80% material recycling rate.
For Subaru’s concept car, MJF enabled the production of four unique, detachable fender flare parts, each serving a different function—from a smartphone speaker holder to a key locker for activities like surfing. “3D printing frees us from the constraints of traditional molds, significantly enhancing our design capabilities,” said Kanenori Susaki, Manager of Subaru’s Accessories Planning Department. “This technology allows us to offer more personalized and enjoyable options to our customers.”
Echoing this perspective, Yu Inoue, Sales Manager at DMM.make 3D Print, remarked, “HP’s Multi Jet Fusion technology provided the precision and speed necessary to meet our objectives within a limited timeframe. We’re excited to explore further applications of this technology in collaboration with HP.” Nobuki Okado, Managing Director of HP Japan Inc., emphasized the broader implications: “Our Jet Fusion platform empowers industries to embrace flexible design and sustainable manufacturing. Partnering with Subaru showcases how additive manufacturing can transform traditional production methods to meet evolving industry needs.”
3D Printing in the Automotive Industry
Italian 3D printer manufacturer Prima Additive and robotics firm Comau have developed a high-speed brake disc coating system for automotive company Stellantis. The system employs Directed Energy Deposition (DED) 3D printing technology to apply a thin, resilient metal layer onto brake discs, significantly reducing particulate emissions caused by brake wear. According to Prima Additive, this 3D printing-based coating process can decrease brake disc degradation-related pollution emissions by 80%, aligning with the European Union’s upcoming Euro 7 standards, which mandate a 27% reduction in brake disc emissions by 2027.
Similarly, CRP Technology, an additive manufacturing materials and services provider, collaborated with MoRe Modena Racing, a student team from the University of Modena and Reggio Emilia. Together, they produced the M24-LH hybrid race car, which won the 2024 Formula Student Austria competition—the first Italian team to achieve this feat. The race car incorporates key aerodynamic and structural components 3D printed using CRP Technology’s proprietary Windform materials. These advanced composites offer high strength-to-weight ratios, essential for competitive racing performance.
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Featured images showcase the Subaru Legacy Outback Booster Package Concept Car, A part that becomes a speaker and The MoRe Modena Racing team. Photos via HP and CRP Technology.