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3 min read
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5 hours ago
At PIX Moving, we have one simple goal: to build a more sustainable, compact, customizable electric vehicle that’s truly one-of-a-kind. Recently, we embarked on an exciting journey to revolutionize how we manufacture these vehicles — by using 3D printing technology. But, as with any innovation, this adventure came with its own set of challenges.
PIX Moving’s 3D Printing Digital Factory
When we first dove into large-scale metal 3D printing, we quickly encountered technical hurdles. One of the biggest challenges was dealing with the vehicle’s complex body structure, where the robotic arms occasionally hit machine limits. Another roadblock was the print angle. Some parts needed to be printed at steep angles, risking material collapse under high heat. This quickly became clear: overcoming gravity on Earth wasn’t going to be easy, and it would require more advanced algorithms to push the boundaries of what we could achieve.
Through countless trials and errors, we began to fine-tune print speeds and temperatures. After experimenting with various settings, we found the sweet spot that allowed for optimal cooling times on different tubular cross-sections, preventing material collapse. To tackle the print angle issue, we added external axes that kept the angles within the ideal range. Slowly but surely, our designs and algorithms started to improve, paving the way for new possibilities in structural design.
Robotic Arm
One of our key breakthroughs came when we focused on optimizing the breakpoints and connection points of printed parts. The goal was simple: ensure everything integrated seamlessly with the printing process. After testing multiple approaches, we landed on a solution — using a single-spiral print method. This reduced unnecessary arcs, minimizing surface scars and cutting down on wasted print paths. The result? Increased efficiency and stability during printing. But this wasn’t just about tweaking numbers; it was about constantly analyzing data and pushing the limits of what we thought was possible.
In addition to these technical advancements, we paired generative design with 3D printing. This combination allowed us to optimize the material’s performance through structural topology, dramatically reducing the vehicle’s weight. This wasn’t just about making the car lighter — it was about highlighting the true potential of 3D printing, enabling the creation of complex structures that traditional manufacturing simply can’t achieve. The result? A more efficient production process and the flexibility to design like never before.
Ultimately, we succeeded in printing our very first small electric vehicle designed for two people. The entire body and chassis were created using 3D printing. It felt like we were bringing a robot to life — every challenge we faced was met with creativity and ingenuity. We even temporarily named it the PIX Robo-EV to capture its futuristic and innovative nature.
Robo-EV Power By PIX Moving
While this is just the beginning of our journey, it marks a major breakthrough in the world of small electric vehicles. We’re still fine-tuning, but the potential for customization and more efficient production is enormous.
So, what do you think? Could 3D printing and generative design be the game-changer the automotive industry needs? Could this be the key to unlocking the future of manufacturing? I’d love to hear your thoughts and start a conversation!