The first 3D-printed plastic car is as strong as steel and half the weight
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Cars are big and heavy, and that means they use a lot of energy while traveling. It’s easy to understand why these behemoths have traditionally been so weighty, though: It takes countless parts to make a modern car, and it’s mostly made out of steel for structural stability. That’s all changing, however, now that large-scale 3D-printing is becoming a reality. These new cars can use less parts and lighter materials to offer the same functionality and safety with less complexity and energy required. With the Urbee 2, Kor Ecologic is making a small two-passenger vehicle with a 3D-printed exterior. It’s highly efficient, light, and extremely safe in spite of being made of plastic.
In an article on Wired, the Urbee 2′s lead designer Jim Kor talks in-depth about the process being used to create this lightweight aerodynamic marvel. Using the Fused Deposition Modeling (FDM) method, thin layers of plastic are sprayed one after the other for about 2,500 hours until an entire car exterior is created. Thanks to the customizability afforded by this production method, different thicknesses and patterns can be used to reinforce the structure. This leaves us with a product as strong as traditional cars, but at a fraction of the weight.
The Urbee 2 will sport three wheels and weigh in at a mere 1,200 pounds (544kg). It’s not quite the same as a traditional car, so Kor believes that many regulatory bodies will require this beast to be registered as a motorcycle. That’s not to say it will be less safe than traditional cars, though. In fact, Kor is aiming for the Urbee 2 to pass the inspection required by the 24 Hours of Le Mans. This 3D-printed beauty will feature a metal roll cage to prevent collapsing or crushing during an accident. “Our goal with the final production Urbee is to exceed most, if not all, current automotive safety standards,” says Kor. (See: What is 3D printing?)
There are still numerous aspects of the Urbee 2 that need to be worked out. The final price isn’t set yet, but the original prototype Urbee was roughly $50,000. Also, the problem of repairing 3D-printed cars remains to be solved. The chassis is essentially one single piece of plastic, so if one area breaks, the whole exterior might need to be replaced. That’s a real problem that will need to be addressed, but it’s certainly not a deal breaker. If a 3D-printed car that gets outstanding mileage while providing superior safety is available, it will turn heads and change expectations. Combined with progress being made in electric engines and battery technology, 3D-printed lightweight cars might just be the next step to more efficient and affordable travel.