Case Study: KOR EcoLogic achieves the world’s first fully 3D‑printed car body for the fuel‑efficient Urbee with Stratasys

Stratasys 3D Printers Build Urbee, First Prototype Car Toi Have Entire Body Created with an Additive Process

KOR EcoLogic, led by Jim Kor, set out to design Urbee, a two‑passenger, ultra‑efficient car that would be environmentally responsible and aerodynamic (target Cd ≤ 0.15). Faced with long lead times and costly tooling from traditional FRP/fiberglass methods, KOR turned to Stratasys — using Dimension 3D Printers and Fortus 3D Production Systems (FDM technology) — to realize a prototype body made entirely with additive manufacturing.

Working with Stratasys and RedEye On Demand, KOR printed the Urbee’s exterior panels in ABS, producing large, full‑scale parts in weeks rather than the months required for fiberglass molds, while enabling rapid design changes and eliminating tooling. The Stratasys solution delivered a prototype with a measured Cd of 0.149 and projected fuel economy over 200 mpg highway (100 mpg city), cut lead time and cost, and proved additive manufacturing feasible for whole‑body automotive prototyping.

KOR EcoLogic

Jim Kor

President and Senior Designer