Mercedes Greenlights 3D-Printed Spare Parts for Vintage Cars

The automotive industry’s embrace of 3D printing is growing stronger by the day. This technology opens up new design possibilities, ensures precise component production, accelerates delivery times, and cuts costs. Developing parts via 3D printing from a three-dimensional digital design file has become a top priority for carmakers. The real challenge for companies and startups is creating components that can meet strict load-bearing requirements—an innovation that could fundamentally change how vehicles are built.

For now, major automakers are focusing on spare parts—and Daimler AG is no exception. Active in 3D printing since 2016, when it began producing replacement parts for its Commercial Vehicles division, Mercedes today is rolling out additive manufacturing with a “powder bed” process. Using one or more laser beams, this method sinters or fuses metal powder to form the exact geometry of the desired part, now extended to the spare-parts segment for historic models. Thanks to three decades of R&D experience—primarily at the Daimler Research Group in Ulm—Daimler AG is poised to expand its offering.

After “clearing the rigorous Mercedes-Benz quality standards,” several spare parts for classic models are set to hit the market. Among them is the support rod for the interior rearview mirror of the legendary Mercedes 300SL Coupé (“W198” series). Also already in production are candle holders, onboard tool kits, and sliding rollers for the sunroof, designed for Series W110 (1961–1968), W111 and W112 (1959–1971), and W123 (1976–1985).

The famous Gullwing’s interior mirror support, produced from 1954 to 1957, is now available as an original aftermarket part through the Mercedes-Benz Classic Center network. To stay true to the original method, it’s cast in aluminum alloy and then given a high-quality chrome finish. The only practical difference is size: the original measured 42.5 mm long, while the new 3D-printed version is 107.5 mm.

The spark-plug holder—designed to seat the plug before tightening—is made from durable thermoplastic polyamide. This tool was part of the original onboard kit, but here it’s been improved: instead of a female connector, a custom magnet now secures the plug. The PA12 polyamide material is also used for the sunroof roller kits.

Ford has continually advanced additive manufacturing since it acquired the world’s third 3D printer in 1988, using it extensively during design phases. Opel has begun producing plastic tooling for several European plants. BMW Motorsport employed 3D-printed aerodynamic parts on the M8 GTE during the most recent racing season, while the BMW Group unveiled 3D-printed interior panels for the Mini JCW Concept at the 2017 Frankfurt Motor Show.

Today’s newest 3D-printing processes leverage “intelligent” software capable of rapidly creating novel materials and metal alloys with unprecedented precision. Volkswagen produced roughly 2,000 3D-printed parts for its I.D. R Pikes Peak prototype, which won the “Race to the Clouds” last June. And at CES 2017, Divergent 3D showcased Blade, a concept vehicle built entirely through additive manufacturing. Divergent has specialized in 3D-printed auto parts for several years and, in fall 2016, signed a collaboration agreement with PSA Group to develop joint additive-manufacturing projects.