Case Study: Aptiv achieves 16-week serial production and 50% faster time-to-market with Carbon DLS

Aptiv - Customer Case Study

Aptiv, a global mobility technology company, needed a trailer‑tow connector cap for Ford Super Duty trucks that met strict automotive standards (USCAR‑2 and ISO 9000) and maintained a seal at 105°C. Facing low‑volume, critical‑part production constraints and aggressive cost and schedule targets, Aptiv partnered with Carbon (using Carbon Digital Light Synthesis™ and the Carbon EPX 82 material) and manufacturing partner Fast Radius to find a faster, tool‑free solution.

Carbon’s DLS technology and EPX 82 material, combined with Fast Radius’s production expertise, enabled tool‑free serial production that passed PPAP and all required validations and met performance targets. The Carbon‑led solution shortened time‑to‑market from 33 to 16 weeks (about 50% faster), cut cycle time by 50%, eliminated tooling expenses, and moved inventory to on‑demand production via the Fast Radius Virtual Warehouse.

Aptiv

Jerry Rhinehart

Additive Manufacturing Technology Manager