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Supercar head and tail light casings using plastic AM

Rimac Automobili recently used our plastic Additive Manufacturing (AM) services to produce the headlamp and tail-light casings for the prototype of their latest electric Supercar, the Concept_One.

Built in Glass-Filled Nylon, they were then coloured black using our permanent surface colouring process by our team of in-house finishers.

The Glass-Filled Nylon material offers high levels of strength and functionality within the casings, and Rimac Automobili then hand-crafted the headlights to contain 58 high-power LEDs. Each headlight is equipped with a unique ventilation system to ensure a clear and sharp lens projection.

The rear lights serve many purposes, including aerodynamics and cooling. Integrated tunnels lead airflows through the radiators of the rear cooling systems into the low-pressure field behind the car. The aerodynamically shaped lights work together with openings in the carbon-fibre bumper and rear diffusor as the Concept_One cuts through air at speed.

Additive Manufacturing, or 3D Printing as it’s also referred to, builds parts directly from CAD data, so complex design features can be incorporated into the CAD which are then accurately replicated during the build – so tunnels, channels and voids can be easily built, as well as text or logos on the parts. Inspiring designers and engineers to create parts specifically for the AM process, they are freed up from previous design constraints. AM removes the need for conventional tooling and creates parts that were previously impossible using conventional manufacturing methods.

Plastic 3d printed head and tail lights    Headlight using plastic additive manufacturing






Rear Lamp made in Nylon 3d printing    rear lamp






Rear Lights in 3d printed nylon    Text detail using plastic 3d printing






Rear lights show text in 3d printing    Rear lights show text in 3d printing

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