Case Study: CALLUM achieves low-volume, lightweight custom car interiors with Stratasys 3D printing (FDM + SAF)

Making low-volume auto production possible with 3D printing

CALLUM, the UK design house founded by Ian Callum CBE, faced the challenge of retrofitting the ultra-low‑volume C‑X75 interior to modern comfort standards without incurring the high cost and long lead times of bespoke composite tooling. To solve this, CALLUM partnered with Stratasys and turned to additive manufacturing, specifically Stratasys’ FDM® and SAF® technologies (including FDM Nylon 12CF), to avoid one-off fabrication tools and accommodate complex, lightweight parts.

Stratasys produced FDM parts for strong, lightweight components (notably carbon-fiber‑reinforced speaker enclosures) and SAF parts for complex B-surface mounts and clips, enabling precise fitment and structural rigidity. The result was faster delivery and lower costs for the limited production run, successful mounting of heavy subwoofers with no loss in audio performance, and a repeatable, tooling‑free workflow CALLUM now relies on—demonstrating Stratasys’ ability to reduce tooling expense and accelerate custom auto production.

CALLUM

Charlie Stamp

Engineer