Contact
Installez votre système LFAM Installez votre système LFAM
Imprimez des pièces en 3D avec nous Imprimez des pièces en 3D avec nous
Contact Contact
From digital to track: mold-free sports car roof powered by robotic LFAM technology image

Caracol has successfully delivered a large-scale sports car roof through additive manufacturing, leveraging its advanced robotic additive manufacturing technology, Heron AM. By eliminating the need for molds, the project combines structural performance with high-end aesthetics, redefining advanced manufacturing in the automotive industry.caracol-car-roog-robotic-lfam4

The result is a faster, more flexible production approach, achieving a 40% reduction in lead time while enabling on-demand manufacturing and high-value customization for the transportation industry.

Developed with ES Garaj and the new LFAM Center, this case highlights the microfactory approach as a foundation for distributed manufacturing. It features a fully digital manufacturing workflow, from CAD to finished part, enabling faster, more flexible production close to the point of use.caracol-car-roog-robotic-lfam2

Mold-free manufacturing for large-scale automotive components

The project addressed a key limitation in traditional automotive manufacturing: the dependency on molds for large composite or metal parts. For components such as a racing car roof, conventional processes like sheet metal forming or fiberglass molding require dedicated tooling, long setup times, and limited flexibility in design iteration.

By adopting Caracol’s Heron AM, the component was produced in a single, mold-free printing process, directly from the digital model using large scale additive manufacturing. This enabled the integration of functional geometries, such as ribs, reference features for trimming, and localized reinforcements, within the print itself, reducing downstream complexity.

The resulting part is a monolithic structure with no joints or assembly steps, ensuring improved structural continuity and repeatability. Mechanical performance targets comparable to traditional metal sheet solutions were achieved through a hybrid additive manufacturing process combining polymer and composite technologies.Caracol-robotic-lfam-car-roof5

Hybrid manufacturing workflow: from LFAM production to structural optimization

The manufacturing process combines large-format additive manufacturing with a controlled post-processing chain designed to meet both structural and surface quality requirements. The part was printed using ABS reinforced with carbon fiber (ABS + 20% CF), leveraging advanced materials for 3D printing to ensure dimensional stability and stiffness.

Key production details include:

  • Robotic system: Heron AM – HV extruder
  • Material: ABS + 20% CF
  • Nozzle size: 5 mm
  • Size: 1420 × 2230 × 510 mm
  • Weight: 30 kg
  • Print time: 27 hours

Following printing, the component underwent trimming and surface preparation, supported by pre-designed features embedded during the LFAM phase. A critical step was the fiberglass hand layup applied to the inner surface, which compensates for anisotropy inherent in layer-based manufacturing and enhances load-bearing performance.

Material compatibility and adhesion were validated through mechanical testing, enabling the selection of optimal resins and fillers for long-term durability. Subsequent bodywork, coating, and polishing phases transformed the near-net-shape print into a component with automotive-grade surface finish, suitable for end-use parts in the transportation industry.Caracol-robotic-lfam-car-roof3

LFAM Center: a new hub for robotic additive manufacturing in Turkey

This project is enabled by the LFAM Center in Turkey, a new production hub dedicated to industrial 3D printing and large format additive manufacturing. Powered by Başaran, Omniform, and Otostech, and leveraging Caracol’s LFAM technology, the center is driving the adoption of advanced manufacturing technologies at industrial scale.

By combining robotic additive manufacturing systems with the microfactory model, the LFAM Center unlocks a new production paradigm, where mold-free manufacturing, mass customization, and on-demand fabrication enable faster innovation, reduced costs, and greater flexibility for the automotive and transportation industries.Caracol-robotic-lfam-car-roof8

Ready to unlock your next project?

LET'S TALK

Projets connexes

Découvrez nos projets