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Bringing LFAM to industrial production for advanced applications in the automotive sector image

Large format 3D printing is transforming how automotive components are designed and developed, enabling greater flexibility, faster iterations, and reduced costs. Caracol’s LFAM technology allows manufacturers to produce complex geometries, functional prototypes, and custom parts without the constraints of traditional tooling.

With its Heron AM robotic platforms, Caracol supports advanced applications across multiple industries, combining additive manufacturing with processes such as CNC machining to meet both functional and aesthetic requirements.

Production with Heron AM and ABS carbon fiber

Caracol collaborated with Torino Crea, an Italian company with over 15 years of experience in automotive design and prototyping, to integrate LFAM into their production workflow.

Through this partnership, Torino Crea adopted Heron AM to produce master models, molds, and full-scale mock-ups for automotive, railway, and aerospace applications. A key project involved the design and production of a functional front bumper mock-up, engineered and manufactured using robotic LFAM.

Caracol supported the team in redesigning the component for additive manufacturing, enabling a fully industrialized and repeatable process.

Production data

  • Technology: LFAM Heron AM 400 (HF extruder) + CNC post-processing
  • Material: ABS 20CF
  • Size and weight: 1800 × 400 × 400 mm, 75 kg
  • Nozzle size: 13 mm
  • 3D printing time: 9 hours
  • Production approach: Single monolithic print, no molds or manual assembly required

Benefits and industrial value

The adoption of LFAM enabled Torino Crea to significantly improve efficiency and scalability in automotive development processes:

  • Cost reduction: Up to 50% savings compared to traditional manufacturing methods
  • Lead time reduction: Up to 50% faster production cycles
  • Waste reduction: Up to 50% less material waste
  • Process simplification: Single-piece production eliminating gluing and manual assembly
  • Design flexibility: Ability to produce complex geometries and full-scale functional mock-ups
  • Industrial repeatability: Integration of LFAM into established workflows for scalable production

This collaboration demonstrates how large-format additive manufacturing can be successfully industrialized within automotive workflows, enabling faster development cycles, improved efficiency, and high-quality results for advanced mobility applications.Stampa2 - 1920x1080

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