Case Study: Delphi achieves rapid functional prototyping and end-use part production with Carbon's M1

Delphi leverages the M1 for prototyping and final part production

Delphi, a long-standing automotive supplier, faced shrinking product development timelines and the need to move beyond basic prototypes to functional, end-use parts. Traditional methods like injection molding required costly tooling and 6–12 week lead times (plus ~4 weeks for revisions), while earlier 3D printing materials delivered only about 50% of the mechanical properties Delphi needed. To address these challenges Delphi partnered with Carbon and began using the Carbon M1 and CLIP process with engineering-grade resins.

Using Carbon’s M1 and materials such as EPU, FPU and RPU, Delphi began producing isotropic, smooth-finish parts suitable for functional validation and short-run production. Carbon’s solution enabled true part validation—Delphi plans to install a batch of connectors into a 25-car fleet for road and validation tests—and eliminated long prototype tooling waits, opened low- and medium-volume production opportunities, and allowed engineers to redesign parts for lighter weight and fewer assemblies. Carbon’s technology delivered the material properties and speed Delphi needed to compress development cycles and move from prototyping to final part production.

Delphi

Jerry Rhinehart