Case Study: Mercedes-Benz achieves large-format bumper prototyping with ExOne's High Speed Sintering

Mercedes-Benz prints a PA12 bumper in 1,000 x 550 x 190 mm with ExOne

Mercedes-Benz faced the challenge of producing a large-format prototype front bumper for its C220d model without incurring the high tooling costs and multi-part assembly associated with traditional injection molding. The automotive manufacturer partnered with vendor ExOne to utilize its High Speed Sintering (HSS) process via the VX1000 HSS system to create the part more efficiently.

ExOne's solution enabled the production of the bumper as a single, large-format PA12 part with high dimensional accuracy, eliminating tooling costs and reducing the number of individual components. The result was a stable prototype produced in days rather than weeks, demonstrating the economic viability of additive manufacturing for large plastic parts and proving its strategic value for prototyping and small-series production.

Mercedes-Benz