Case Study: Aptiv achieves 20-week faster time-to-market and reliable low-volume automotive production with Fast Radius

Aptiv - Customer Case Study

Aptiv, a global technology company for safer, greener mobility, needed an innovative low-volume production solution for a trailer-tow connector cap for Ford that would meet stringent automotive standards (USCAR‑2 and ISO 9000). Working with Fast Radius and using Carbon’s Digital Light Synthesis (DLS) technology and Carbon EPX 82 material, Aptiv pursued a repeatable, tool‑free additive manufacturing approach to protect electrical contacts from harsh environments and accelerate time to market.

Fast Radius implemented industrial‑grade Carbon DLS production combined with optimized build layouts, proprietary digital‑thread software, standard operating procedures, and rigorous quality controls, passing Aptiv’s on‑site audits and completing PPAP to become an approved supplier. The solution delivered consistent, scalable production of thousands of parts, storage in the Fast Radius Virtual Warehouse, streamlined manufacturing, and a measurable 20‑week reduction in time to market.

Aptiv

Jerry Rhinehart

Additive Manufacturing Technology Manager