Case Study: Vauxhall Motors achieves 6‑month delay avoidance and £10,000+ savings by validating critical tooling with 3D Systems

3D Printed Prototypes Streamline Vehicle Process Equipment

Vauxhall Motors Ltd. (the UK arm of General Motors) needed to introduce a modified process hanger and a new critical support part for vehicle bodies. Because the final parts would be cast steel—with long lead times and high cost—a design mistake could have caused up to six months’ delay and more than £10,000 in extra expense.

Vauxhall worked with InfusionTech to produce post-processed, infused 3D-printed prototypes (ProJet 660) that delivered the required accuracy and strength for on-line testing. The prints allowed CAD-fit validation, adjustments to load/unload stations, correction of a top-pin height issue, and early robot programming, enabling the team to order the final cast parts confidently. The approach avoided costly rework and major delays, saved significant time and money, and Vauxhall now plans to continue using 3D printing in its design process.

Vauxhall Motors

Graham Cooper

Senior Planning Engineer