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Auto Additive and its partners, GKN Forecast 3D and Headlights.com have developed a new 3D-printed solution capable of producing OEM-quality mounting tabs using HP printer technology and industry-grade, OEM-compatible polypropylene materials. This breakthrough allows previously damaged headlights with missing tabs to be refurbished to industry standards, backed by rigorous testing.
The end result delivers various benefits to the industry and environment, including reduced repair costs, shorter cycle times, and diverting approximately 8 pounds of plastic waste per repaired headlight from landfills. Additionally, it offsets the carbon footprint by eliminating the need to produce, stock, and ship new headlights to repair shops.
This innovative approach utilizes advanced 3D printing to repair damaged headlight bases by directly fuse welding 3D printed polypropylene tabs onto the original part. The newly formulated polypropylene material enabling this process is 3D printed on HP 5200 Multi-Jet Fusion technology, these machines can cost more than $600,000 and are already widely used by OEMs in their end-use parts manufacturing.
In the USA, nearly a million headlights are purchased annually for collision repair, often discarded due to broken plastic mounting tabs. This results in significant repair costs and landfill waste, with headlights for general makes and models ranging from $300 to $4000 each, while prestige vehicle headlights can cost significantly more.
This industry-first solution is set to launch in the USA and Canadian markets through several launch partner part suppliers in late September, with various other parts expected to benefit similarly. Several MSOs, including the Boyd Group, have expressed interest in this exciting development, with a representative on hand to witness the presentation and concept firsthand.
Discussions are underway with local and overseas part suppliers, including OEMs, to explore how this technology and solution can support circular parts initiatives, especially as many leading OEMs intensify efforts to extend parts lifecycles, particularly around damaged headlights.
