AMS 2025

The Transformative Power of 3D Printing in the Collision Industry: Saving Cost and the Environment

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The collision industry is abuzz with the potential of 3D printing technology and advanced materials such as polypropylene.

One of the most significant applications is the potential repair of damaged parts, including headlights, by printing missing base tabs and attaching them using various fusing, adhesive, or attachment methods.

This innovation not only brings substantial economic benefits to repair shops and insurers but also has a profound positive impact on the environment.

Revolutionizing Headlight Repairs using 3D Printing

Traditionally, when a headlight’s base tab breaks, the entire unit is often deemed irreparable and must be replaced. This replacement process involves significant costs and logistical challenges, including manufacturing, storing, and shipping new parts. Headlight costs are a key factor in rising repair expenses, which, in turn, drive up vehicle insurance premiums.

3D printed headlight tabs. Image courtesy of Auto Additive. 

However, 3D printing now enables the production of high-quality, OEM-grade replacement tabs that can be welded onto the existing headlight, restoring its functionality and extending its lifespan. This capability is particularly significant for the collision industry, where even minor damages to parts like headlights can result in high repair costs. By utilizing 3D printing technology, repair shops can source these replacement tabs on demand, reducing the need to maintain extensive inventories and minimizing wait times for repairs.

This enhances operational efficiency and reduces costs for both repair shops and customers.

Standardization and Testing

It has been documented that there is a growing community of auto suppliers for repair that are made with low-grade materials using consumer or prototype printers and parts then sold to an unsuspecting repair industry as end use parts.

One of the key aspects of this supply chain is the importance of industry-ready, OEM-compatible parts provided by reputable suppliers who ensure transparency regarding the materials they use, the testing they perform, and the printing technology they adopt. OEMs are rapidly adopting 3D printing for end-use parts, utilizing various industry-grade machines for their manufacturing processes. For any collision parts supplier, the first step is to use these same machines and technologies to assure the industry that these parts are suitable and safe. By adhering to stringent standards and conducting rigorous testing, suppliers can guarantee that their 3D printed parts meet or exceed the quality and safety benchmarks set by OEMs, thus fostering trust and reliability in the repair market

Environmental Impact

The environmental benefits of 3D printing in headlight repairs are considerable. By avoiding the need to manufacture new parts, the industry can significantly reduce its carbon footprint. The production of new automotive parts involves substantial energy consumption and greenhouse gas emissions, from raw material extraction and processing to manufacturing and transportation.

In contrast, 3D printing replacement tabs require significantly less energy. The process involves additive manufacturing using materials like polypropylene (PP), which can be done locally, reducing the need for transportation and storage. Additionally, 3D printing minimizes material waste, as parts are produced layer by layer using only the necessary amount of material.

Diverting Waste from Landfills

One of the most critical environmental impacts of 3D printing in the collision industry is its ability to divert waste from landfills. Each headlight repaired instead of replaced represents approximately seven pounds of material that does not end up in a landfill. Given the millions of vehicles on the road and the frequency of headlight damage, this can translate into a significant reduction in automotive waste.

Repable headlight with tabs missing going into landfill

This reduction in waste has far-reaching implications. Landfills are major sources of pollution, emitting harmful gases like methane and contributing to soil and water contamination. By reducing the volume of waste that ends up in landfills, the collision industry can play a crucial role in mitigating these environmental impacts.

Economic and Operational Benefits

Beyond the environmental benefits, 3D printing technology offers several economic and operational advantages for the collision industry. The ability to produce replacement parts on demand can lead to substantial cost savings. Repair shops can reduce their dependence on external suppliers, minimize inventory costs, and avoid delays associated with ordering and shipping new parts.

Furthermore, the flexibility of 3D printing allows suppliers to produce parts for a wide range of vehicle models and makes. This versatility is particularly valuable in an industry where parts compatibility can be a significant challenge. By having the capability to print custom parts as needed, repair shops can improve their service offerings and enhance customer satisfaction.

Future Outlook

The potential of 3D printing in the collision industry extends beyond headlight repairs. As technology continues to advance, a broader range of automotive parts will likely become suitable for 3D printing. This could further enhance the industry’s ability to repair rather than replace damaged components, leading to even greater environmental and economic benefits.

Moreover, the integration of 3D printing technology into the industry’s is driving innovation in other areas, such as custom parts manufacturing, rapid prototyping, and on-demand production of specialized tools and equipment.

The flexibility and efficiency offered by 3D printing can drive significant improvements in the industry’s overall operational capabilities and have a huge impact on our environment from reducing the industry’s carbon footprint to diverting the millions of plastic parts out of landfill.

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