Case Study: Karsan cuts vehicle part costs and weight with Stratasys F770 3D printing

Karsan Cuts Vehicle Part Costs and Weight with F770 3D Printing

Karsan, a Turkish vehicle manufacturer focused on electric mobility and lightweight vehicle design, needed to replace metal parts with lighter plastic alternatives while keeping strength, compliance, and cost under control. Traditional injection molding was too expensive for low-volume custom parts, and outsourced sheet metal production added long lead times and delayed time-to-market. Stratasys F770 3D printing was used to support this effort.

Stratasys implemented the F770 large-format FDM 3D printer so Karsan could produce full-size ABS parts in-house with soluble support, enabling complex geometries, fewer assembly steps, and faster iteration. The result was an 80% reduction in production cost, from €2,500 to €500 per part set, while shortening production cycles by 3–4 weeks compared with outsourced sheet metal options. The printed parts were also lighter, helping Karsan meet government weight limits and improve vehicle design efficiency.

Karsan