Rivian and Ford Expand 3D Printing Across Auto Production

Automakers are expanding industrial 3D printing across manufacturing operations as Rivian, Ford Motor, and General Motors seek to lower production costs and accelerate development. The companies are using the technology in factories, research facilities, and selected vehicle production processes, with Rivian investing more than $5 million in printing equipment.

The technology, also known as additive manufacturing, creates three-dimensional objects from digital designs by depositing materials layer by layer. Depending on the application, printers can process plastics, composites, ceramics, and metals to produce vehicle components, factory tools, and research equipment.

Rivian has expanded its printing operations beyond prototyping to include manufacturing support and selected production components. The electric vehicle manufacturer has also increased employee access to the technology at its facilities.

Jared Beck, head of Rivian's additive manufacturing, said the company is moving toward broader adoption across its operations.

"At this point, we don't have a choice but to scale up and begin using it through all factions of Rivian," Beck told CNBC during a tour of the company's 3D-printing operations in suburban Detroit.

He described the broader strategy as an effort to make the technology accessible throughout the organization.

"We're going to be democratizing 3D printing for the entire company."

According to Rivian, its investment in 3D-printing machines has exceeded $5 million, while annual material expenses have reached approximately $1.7 million. Beck said the equipment generally recovers its costs within a year.

The technology can reduce supplier tooling expenses, simplify logistics, and shorten manufacturing timelines. Beck said certain components that previously required weeks to produce can now be manufactured within days or even hours.

He identified faster production as the primary benefit, alongside substantial financial savings.

"It's well in the millions [for savings], but the main thing is speed for Rivian," Beck said.

Rivian's latest expansion includes machines capable of producing flexible silicone components. The company has also installed a dedicated printing area at its Normal, Illinois, factory, allowing employees to produce parts on demand.

The manufacturer has applied 3D printing to electric-motor models for fluid testing, screw guides, tooling, stamping press inserts, and selected production components. These include trim pieces designed to fill gaps in some early vehicle builds.

Beck said broader employee access would help engineers obtain physical components more quickly during development.

"3D prints should be readily available for every engineer so that they can make a part and get it in their hands as soon as possible," Beck said.

Ford has also expanded additive manufacturing across its production facilities. Rather than concentrating its equipment in one central location, the automaker operates dedicated 3D-printing departments at multiple factories to manufacture and distribute tools and components.

One recent initiative involves a vending machine supplying 3D-printed tools for F-150 pickup truck production near the company's headquarters in Dearborn, Michigan.

Gregory Foresi, a Ford mechanical engineer who managed the company's 3D-printing laboratory at the River Rouge factory from 2024 until the previous month, said the vending system gives production supervisors easier access to necessary equipment.

"By putting the vending machine up, all the team leaders have access," Foresi said.

He explained that centralized distribution also helps organize inventory and reduces the need to store large quantities of printed components inside the laboratory.

"We're able to keep that thing stocked rather than have a bunch of parts laying around in the lab. So that's been pretty huge."

Foresi previously used approximately two dozen 3D printers to manufacture thousands of tools. Some designs originated from factory employees and included torque bit sockets, hood jackers, and hand tools for smoothing adhesive.

Ford employees can request specific tools and vehicle components through an application. The company's additive manufacturing teams then help develop the designs or determine which items should be produced.

Production times vary depending on the component, ranging from several hours to days or weeks. Foresi said the technology allows Ford to create specialized tools more quickly and, in many cases, at lower costs.

The company has also used 3D printing to prevent manufacturing interruptions. At one point, a large machining wheel required for assembly line operations was unavailable, so Ford produced a temporary replacement while waiting for a permanent supplier component.

Foresi acknowledged that the printed component did not match the performance of the original equipment but helped maintain factory operations.

"They didn't perform as well, and it's not really a replacement for the ones that we were purchasing, but they kept the plant running," Foresi said.

Ford said it expects to establish 3D-printing laboratories at more than 23 factories by the end of 2026. Its official program already includes more than 200 machines, with additional printers operating outside the program.

General Motors is pursuing a similar approach, using 3D-printed components in research and development, factory operations, and selected low-volume vehicle production. The Detroit-based automaker has recently expanded its use of industrial Stratasys printers, which can cost hundreds of thousands of dollars depending on their applications, training requirements, and certification needs.