Daimler Truck and Bus Solves Spare Parts Supply with 3D Systems’ Additive ManufacturingDaimler Truck and Bus Solves Spare Parts Supply with 3D Systems’ Additive Manufacturing

The maker of Mercedes-Benz buses can now print metal parts in repair shops rather than stocking and shipping parts.

Dan Carney, Senior Editor

January 31, 2025

3 Min Read
Mercedes-Benz buses like this one can be back on the road more quickly using locally printed 3DP parts.
Mercedes-Benz buses like this one can be back on the road more quickly using locally printed 3DP parts. Daimler Truck and Bus

At a Glance

  • Producing parts on demand can slash delivery time by 75 percent.
  • Digital rights management ensures that printed parts are legal.
  • The market for 3D-printed auto parts is expected to grow to $7.9 billion by 2027.

Keeping all the parts in inventory that are needed to maintain a bus fleet is a costly chore that involves shipping and storing the numerous parts that might be needed, but Daimler Truck and Bus aims to reduce that burden by 3D printing repair parts right in the shop as they are needed.

This promises to not only reduce the logistical burden on bus fleet operators but will also reduce or eliminate instances of buses being off the road while awaiting repair parts from the depot. Daimler predicts that employing 3D Systems SLS 380 printers in their bus repair shops can increase flexibility and efficiency while reducing time to parts-in-hand by as much as 75 percent.

These benefits are what is driving a boom in the automotive parts 3D printing market. According to a research report published by MarketsandMarkets, the automotive 3D printing market is projected to grow from $2.9 billion in 2022 to $7.9 billion by 2027, at a compound annual growth rate of 21.7 percent. 

Most of those parts will be inexpensive plastic bits, the report notes, but Mercedes is currently printing metal parts for its vehicles. Daimler Buses’ certified 3D printing partners will be able to manufacture spare parts locally for a variety of under-hood and interior applications, such as pins, covers, and inserts whose absence could delay a vehicle’s return to service.

Related:Stratasys Is Printing Next-Generation Racing Parts for NASCAR

The first part Mercedes is printing in the SLS 380 is a thermostat housing for old Unimog trucks, a vehicle for which the parts inventory is understandably dwindling and for which tooling for new production makes no financial sense. For buses, the company is printing new fare collection box housings.

“We are very pleased that we are expanding the revolutionary solution with 3D Systems, one of the world’s leading 3D printer manufacturers, and realizing our vision for decentralized spare parts production,” said Ralf Anderhofstadt, head of Daimler Truck and Buses center of competence for additive manufacturing.

While developing the physical capability to print parts is the obviously necessary first step, there are also legal factors to be sorted when manufacturing parts whose design is protected intellectual property. That’s where Mercedes has turned to Oqton for software and Wibu-Systems for digital rights and IP management.

Mercedes_3DP_thermostat_housing.jpeg

"The Digital Rights Management enables us to shorten service times through decentralized production in order to further maximize productivity and revenue for commercial vehicle companies,” said Anderhofstadt. “In addition, the sensible use of industrial 3D printing results in reducing the complexity in the supply chains."

Related:Mercedes Puts Apollo Robot to Work

Bus companies using Mercedes buses and 3DP service bureaus can join Daimler Buses’ network of 3D printing-certified partners by purchasing a license for 3DXpert additive manufacturing software through Daimler Buses’ Omniplus 3D-Printing License eShop.

The “prepare and print” license lets customers decrypt the encrypted Mercedes design files for the parts needed for a specific repair job and then produce the only exact quantity needed on the SLS 380 printer. Daimler Buses plans for 3DP service bureaus to be able to connect any 3D Systems’ polymer or metal 3D printer to the system.  

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“By commercializing this digital service solution, Daimler Buses is not only adopting a new technology; they’re fundamentally reshaping the supply chain for greater resilience and efficiency,” said Jaime Garcia, 3D Systems additive solutions manager for automotive and commercial transportation. “I look forward to seeing how the capabilities grow as we add other polymer as well as metal 3D printers in the future,” he said.

About the Author

Dan Carney

Senior Editor, Design News

Dan’s coverage of the auto industry over three decades has taken him to the racetracks, automotive engineering centers, vehicle simulators, wind tunnels, and crash-test labs of the world.

A member of the North American Car, Truck, and Utility of the Year jury, Dan also contributes car reviews to Popular Science magazine, serves on the International Engine of the Year jury, and has judged the collegiate Formula SAE competition.

Dan is a winner of the International Motor Press Association's Ken Purdy Award for automotive writing, as well as the National Motorsports Press Association's award for magazine writing and the Washington Automotive Press Association's Golden Quill award.

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He has held a Sports Car Club of America racing license since 1991, is an SCCA National race winner, two-time SCCA Runoffs competitor in Formula F, and an Old Dominion Region Driver of the Year award winner. Co-drove a Ford Focus 1.0-liter EcoBoost to 16 Federation Internationale de l’Automobile-accredited world speed records over distances from just under 1km to over 4,104km at the CERAM test circuit in Mortefontaine, France.

He was also a longtime contributor to the Society of Automotive Engineers' Automotive Engineering International magazine.

He specializes in analyzing technical developments, particularly in the areas of motorsports, efficiency, and safety.

He has been published in The New York Times, NBC News, Motor Trend, Popular Mechanics, The Washington Post, Hagerty, AutoTrader.com, Maxim, RaceCar Engineering, AutoWeek, Virginia Living, and others.

Dan has authored books on the Honda S2000 and Dodge Viper sports cars and contributed automotive content to the consumer finance book, Fight For Your Money.

He is a member and past president of the Washington Automotive Press Association and is a member of the Society of Automotive Engineers

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