Volkswagen Autoeuropa: maximizing production efficiency with 3D tools, models and accessories

Volkswagen Autoeuropa, which is responsible for the production of iconic Volkswagen models such as the Scirocco and Sharan and produces 100,000 car models per year, is currently using 3D printing to revolutionize the business.

The facility 3D prints parts that are used every day on the assembly line. Because they no longer rely on outside suppliers to produce parts, models and accessories, costs are lower and lead times are kept to a minimum, from weeks to just a few days.

Volkswagen Autoeuropa: maximizing production

The case of Volkswagen Autoeuropa illustrates how 3D printing can be of real help to the automotive industry. Traditionally, 3D printing was associated with the creation of prototypes, but in the meantime it has started to be exploited for the production of parts, models, accessories and so on.

With 3D printing, complex models can be created, as well as quick modifications and revisions without additional costs and long lead times. Parts can be customized to specific requirements, thus making functionality and performance key design factors.

This 3D wheel protector model was purchased for €800 but can now be printed for just €21. Production times dropped from 56 days to just 10.

External suppliers

• Before working with Ultimaker, Volkswagen Autoeuropa relied on external suppliers for parts and tools.
• These third-party companies usually had a lead time of several weeks to process the models and produce the parts. Therefore, production was significantly slowed down, affecting the flow of Volkswagen Autoeuropa’s business over time.
• Outsourcing the processing of goods proved to be expensive, especially if some design change was required. Sometimes, when making new parts for production, Volkswagen Autoeuropa has to take an approach of test-test-error of the product.
• This option was not convenient when working with other companies.

Save time and money with 3D printing

Following concept validation in 2014, Volkswagen Autoeuropa currently has 7 Ultimaker 3D printers in operation and produces 93% of all externally produced parts in-house. Switching to 3D printing saved 91% on part manufacturing costs and reduced development time by 95%.

With Luis Pascoa, Pilot Plant Director of Volkswagen Autoeuropa, explaining:

«Only by printing the multitude of pieces will it be possible to return to the investments of the past. A plate for the car license plate was made in 35 days, and the price was 400 euros.

With 3D printing, the project was completed in 4 days and the costs were reduced by €10 from the amount.

This delay cost us 180 euros a piece: now it can be 3D printed for just 35 euros.

Development time decreased from 8 to 6 days.” .

During 2016, the company saved approximately €150,000 and €250,000 in 2017.

The initial investment in Ultimaker equipment was fully recovered within 2 months.

In addition to saving time and money, 3D printing tools are much more ergonomic and produce greater operator involvement so that feedback can be more easily implemented into the design process – all of which adds to previous levels of efficiency.

The 3D printed parts produced by Volkswagen Autoeuropa are considered the best in the Volkswagen Group.

Change your workflow

By producing in-house, Volkswagen Autoeuropa can skip the purchasing department and has the ability to develop ideas for new or improved parts together with operators. This option was impossible to apply in the past, since few ideas could be implemented in an organized and timely manner.

A new part can be printed overnight and already tested on the assembly line next to the operators the next morning. Their feedback can be incorporated into numerous design plans until the perfect piece is created. That piece can be printed as many times as needed and at minimal cost.