Small parts instantly, a bumper in a few days: 3D printing accelerates development

Faster and more confidential 

The purpose of the 3D Printing Centre is to accelerate and simplify the development of new vehicles and components. Škoda Auto produces prototype parts in-house that would otherwise require a more complicated or costly process or would have to be outsourced to external suppliers. “Using 3D printing saves us a considerable amount of time. And since all data remains within the company, this approach also offers enhanced confidentiality,” Sova points out, highlighting the advantages of this technology. The 3D printed models can also be recycled.

Small and simple components can be prepared for Technical Development almost immediately, while producing and printing more complex parts, such as large bumper sections, takes approximately three to five days, depending on their complexity. Even this timeframe is significantly faster than outsourcing to a supplier. “Flexibility is another advantage. If changes are introduced during the preparation stage, we can easily and quickly implement them,” Sova explains. 

 
The center's equipment operates virtually around the clock. According to Sova, the largest printers, which use FDM (Fused Deposition Modeling) technology, run for approximately 7,500 hours a year—equivalent to 312.5 days— with downtime occurring only during maintenance, servicing or company holiday. 
 
Each year, the 3D Printing Centre produces around 15,000 parts—some very small, others up to one meter in size. “For example, we print bumpers in several sections and then assemble them,” says Sova. Some parts are used in their raw, unfinished state, but many undergo post-processing, including painting and finishing carried out by other departments such as the model shop or prototype workshop.  

Each of the four technologies used in the center serves different purposes. The most commonly used is fused deposition modelling (FDM) – the classic filament-based printing method also known from home use, only on a much larger scale. These printers can handle parts up to one meter in size, which are often further processed or joined into larger assemblies. The method is used to produce models and prototype parts for aerodynamic testing, design verification, and installation trials. 
 
When parts need to meet more demanding functional requirements—for example, when components must fit together exactly as in the final production model—the Multi Jet Fusion technology is used. It offers higher resolution, meaning almost invisible layering, and provides superior mechanical properties. 
 
The center also uses the PolyJet technology, which serves to produce show models for design evaluation, and stereolithography (SLA), which employs light to cure resin layers. Both SLA and PolyJet methods allow for the use of different materials, which is useful for producing two-component parts.