Tesla Explores 3D Printing for Car Body Innovation

Tesla is currently exploring the use of 3D printing for car bodies. The potential scalability of this method could bring Tesla closer to cutting production costs in half, a strategy reminiscent of Apple's unibody design approach for laptops, which streamlined manufacturing and reduced assembly expenses. 

Elon Musk, Tesla's CEO, has long championed the concept of "unboxed" production, emphasizing the assembly of large sub-units that can be seamlessly connected. Tesla already employs a method known as "gigacasting," which utilizes ultra-high-pressure presses to mold large vehicle components instead of numerous smaller ones. This approach is applied to shape the front and rear parts of their Model Y cars, allowing for faster production compared to other electric car manufacturers. 

This technique involves the fusion of 3D printing with industrial sand, wherein 3D-printed solid sand cores are placed within molds. After the casting process, the sand cores are removed, resulting in a hollow subframe that enhances structural integrity. This approach grants Tesla greater flexibility in terms of cost control, design modifications and production time compared to traditional metal molds. It reduces the time required to develop a new car from the traditional 3-4 years to only 18-24 months.

In the future, the company plans to implement even higher pressure for a new method, which will require additional space. Tesla is expanding its factories in Berlin and India for this purpose. The company also aims to introduce an affordable electric car priced at US$25,000 by 2025. This cost reduction is achieved by avoiding the expenses associated with mold creation, which can reach up to US$4 million and post-testing modifications, which can amount to US$1.5 million.