Case Study: General Motors achieves 70% faster lead times and 56% lighter hemming tools with Stratasys 3D printing

3D printing offers shorter lead times and lighter materials, improving ergonomics of assembly on the Chevrolet Equinox rear wheelhouse hemming

General Motors (GM), a global leader in automotive innovation, faced long lead times and handling risks with the rear wheelhouse hemming tool for the Chevrolet Equinox. Traditionally machined from aluminum, the 75‑pound tool required more than 10 weeks to produce and needed lift assistance, creating schedule inflexibility and potential for sheet‑metal damage. GM worked with Stratasys and tested additive manufacturing using the F900 printer and FDM® ASA thermoplastic.

Stratasys 3D printed the hemming tool on the F900, enabling rapid iteration and lighter materials; the printed tool was produced in three weeks versus the typical 10–13 weeks (a >70% lead‑time reduction). The part weight dropped from 75 to 33 pounds (56% reduction), eliminating lift assistance and improving ergonomics, while total cost fell by 74%, delivering faster, safer, and lower‑cost preproduction tooling for GM.

General Motors