3D Rapid Prototype

Sika is at the forefront of 3D printing innovation, offering advanced solutions that enhance material performance, accelerate prototyping, streamline spare part production, and enable cost-effective low-volume manufacturing. These technologies are revolutionizing automotive production processes while addressing industry-specific challenges. 

Sika has developed an innovative UV-photopolymer for 3D printing that boasts superior heat resistance, making it ideal for demanding automotive applications such as under-the-hood and Body-in-White components. This innovation supports design optimization, rapid prototyping, and testing of high-temperature parts, delivering durability and reliability at reduced costs. For instance, the material has been successfully used in components that endure the electro-deposition (E-Coat) oven process post-Body-in-White assembly. Future developments include expanding the range of durable, heat-resistant polymers with a focus on sustainability across multiple industries. The latest advancements were highlighted at Formnext 2024.

Sika's proprietary heat-reactive materials enable fast 3D printing of functional prototypes, such as SikaBaffle® and SikaReinforcer®, directly from CAD models. This innovation accelerates development cycles by allowing quicker iterations and testing during the design phase. A key example of its impact is the improved validation of multiple SikaBaffle® components for design, fit, and function, significantly enhancing development efficiency.
Looking ahead, advancements in pellet printers promise even faster production of prototypes, reducing lead times and boosting productivity.
 

Sika addresses the challenges of spare parts production through on-demand digital manufacturing. Using 3D printing, parts like SikaBaffle® can be produced even years after End of Production (EOP), eliminating high storage costs, overproduction, and long lead times. Collaborations with OEMs have enabled efficient, on-demand production of aftermarket parts, cut storage expenses while ensuring availability for up to 15 years post-discontinuation.

Future innovations, including Sika’s Digital Source platform, will enable industrial-scale production of manufacturer-certified parts through license management, reducing inventory complexity and enabling localized production.

Robotic 3D printing is transforming low-volume manufacturing by offering a cost-effective solution for small batch parts, such as SikaBaffle®, optimized for speed and design flexibility. This approach is ideal for niche vehicle models or pre-production testing, eliminating the need for expensive tooling. For example, Sika’s small-batch production capabilities are set to support low-volume vehicle manufacturing starting in 2027, demonstrating the viability of additive manufacturing as a bridge between design and mass production.

Future improvements will focus on enhanced automation to minimize manual intervention in slicing and post-processing, as well as advancements in materials to scale additive manufacturing for serial production efficiently.

 With these innovations, Sika is redefining automotive manufacturing through 3D printing, combining precision, sustainability, and flexibility to meet evolving industry needs.