Subaru Used HP 3D Printed Parts for the Legacy Outback Boostgear

3D printing takes another step into automotive production with the collaboration of HP Japan, DMM.com, and Subaru. The additive manufactured car parts were produced using HP Japan’s Jet Fusion 3D printer. The parts were designed and manufactured for Subaru's concept car, the Legacy Outback Boostgear Package.

In developing parts, Subaru wanted to solve various manufacturing challenges while keeping an eye on the future. Challenges in automotive parts development range from mold manufacturing to logistical burdens. Typically, part production requires dedicated molds. With molded parts, design is often restricted by the direction of mold removal, making customization and low-volume, high-mix parts development difficult. Additional issues include inventory management of factory-produced parts and costs and CO2 emissions from transportation.

Multi Jet Fusion technology

The concept car’s name Boostgear represents a "boost" to help customers go places they couldn't go before and do things they couldn't do before. Through the design of playful decorative parts, Subaru proposes new ways of interacting with cars. The newly created parts are intended for future implementation using HP Jet Fusion 3D printers. They incorporate HP’s Multi Jet Fusion technology, which was adopted to balance the required strength and mass production capabilities.

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3D printing was chosen for the design capabilities of additive manufacturing. “We automotive designers have always been constrained by molds, struggling with issues like part separation,” said Kanenori Susaki, manager of Subaru’s Accessories Planning Department, Parts & Accessories Division. “However, by using 3D printing, we are freed from all issues such as the angle of mold removal and the appearance of parting lines, significantly enhancing design freedom. We aim to actively adopt 3D printing, which is suitable for low-volume, high-mix production, to provide customers with more enjoyment.”

Subaru chose to collaborate with DMM.make because of the company’s 3D printing experience and its speedy manufacturing technology. Subaru used the HP Jet Fusion 3D printer to produce four types of removable parts. They were manufactured within a limited timeframe so Subaru could showcase the Booster at the Tokyo Auto Salon 2024.

A part incorporating a magnet, allowing attachment of tools or kitchen utensils. Image courtesy of HP Japan.

A part that becomes a speaker when a user inserts a smartphone, allowing people to enjoy music outside the car. Image courtesy of HP Japan.

A hangar with a shape that takes advantage of the unique features of 3D printing without restrictions like the direction of mold removal. Image courtesy of HP Japan.

A lockable locker for temporary storage of car keys when surfing or enjoying other activities. Image courtesy of HP Japan.

By utilizing HP Jet Fusion 3D printing solution, the need for molds was eliminated, allowing for the development of parts with unique shapes quickly. HP 3D High Reusability PA 12 (Nylon 12) was used as the material, meeting desired properties in terms of heat and weather resistance, as well as sufficient strength.

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Speed of design and production were an important factor given the deadline of the Tokyo show. “We were responsible for shaping automotive parts for the exhibition,” said Yu Inoue, sales manager, 3D Print Division, Entertainment & EC Division at DMM.com. “Since the time from prototype to completion was extremely limited, we adopted HP's Multi Jet Fusion technology, known for its high precision, quality, and fast shaping speed.”

HP noted that the HP Jet Fusion 3D printer is designed for environmentally friendly manufacturing, achieving a high material recycling rate of up to 80%. This method allows parts to be produced anywhere by sending 3D data, eliminating the need for inventory of manufactured parts, which can significantly reduce logistical burdens.