Automotive Industrial 3D Printing
Industrial additive manufacturing case study: Replacing a failed ABS bracket with engineering-grade nylon for improved heat resistance and low-volume production without tooling.
The Problem: Failed ABS Bracket
A local automotive workshop approached us with a broken engine bay bracket. The original part was injection-moulded ABS, but after 18 months of exposure to engine heat and vibration, it had cracked and failed. The manufacturer quoted 6-8 weeks for a replacement mould and minimum order of 500 units.
The workshop needed the part urgently to get the vehicle back on the road. Traditional manufacturing wasn't viable for a one-off repair.
The Solution: Nylon Replacement
We scanned the broken bracket using our industrial scanner and recreated the geometry in CAD. Given the heat exposure, we recommended nylon over ABS for better thermal stability.
The part was printed in nylon with 100% infill for maximum strength. Total production time: 48 hours from scan to finished part.
The nylon bracket has been in service for 12 months without issues, outperforming the original ABS in heat resistance.
- Improved material properties for the application
- Rapid turnaround without tooling costs
- Functional performance exceeding original part