In industries where performance, precision, and efficiency drive success, the ability to quickly produce end parts for prototyping or tooling such as, patterns, layup tools, trimming jigs, or fixtures is essential. Whether it’s a hand layup mould, vacuum mould, manufacturers rely on efficient production methods to keep pace with demand.

Whether it’s automotive manufacturers refining production, transportation companies optimizing fabrication, or motorsports teams pushing the limits of engineering, traditional methods often come with high costs, long lead times, and material waste—slowing innovation and increasing operational burdens.

Large Format Additive Manufacturing (LFAM) changes the game. By harnessing advanced composite materials and scalable production techniques, LFAM enables the rapid creation of lightweight, durable, and customizable tooling with shorter lead times and lower costs.

Say goodbye to traditional limitations and cost of fixture production and the ever increasing material costs of tooling boards (PUR block) and labor-intensive machining processes.

This means aerodynamic moulds for high-performance vehicles, precision fixtures for streamlined assembly, and trimming jigs that enhance fabrication workflows—all while supporting sustainability goals and meeting regulatory demands.

In the fast-paced world of motorsports, where every fraction of a second counts, LFAM gives teams the edge by accelerating production and reducing storage burdens associated with conventional moulding. Across automotive and transportation industries, manufacturers can scale efficiently, cut costs, and meet the growing demand for sustainable, flexible fabrication solutions—without compromising performance.

From prototyping to full-scale production, LFAM empowers manufacturers to scale efficiently, cut costs, and meet the growing demand for sustainable and flexible fabrication solutions across automotive, transportation, and motorsports.

Every race car tells a story—a journey of engineering breakthroughs, design evolution, and the relentless pursuit of speed. Forze Hydrogen Racing, a student team from Delft University of Technology , The Netherlands, is rewriting that story, proving that cutting-edge technology and sustainability can go hand in hand.

Their latest creation, the Forze IX hydrogen racing car, is built to compete against petrol-powered rivals, showcasing hydrogen’s potential as a clean energy alternative. But long before the car hit the track, the team faced a major hurdle—traditional tooling methods were slowing them down.

Forze IX’s rear cover, an essential aerodynamic component, needed to be manufactured with high precision. However, conventional mold-making would take up to Up to 77 days for full production. Of the rear cover. The high cost of €36,000 in Europe and half that in Asia. This molds would be made from MDF making them Heavy and difficult to handle. The Non-recyclable materials, leading to unnecessary waste.

The Breakthrough: 3D Printing with LFAM

Instead of following the old ways, Forze partnered with CEAD to implement Large-Format Additive Manufacturing (LFAM). With Flexbot technology, they could print and machine the mold in just a week, cutting lead time and cost.

The advantages of 3D printing:

• Time savings: 7 days vs. 77 days.
• Cost reduction: €9,860 vs. €36,000 (Europe) / €18,500 (Asia).
• Recycled materials: Printed with Dalthram® T-100GF, a PETG/glass fiber composite from Airtech.
• Recyclability: No need for storage—molds can be ground down and reused. (pikes peak case study)
• Lighter Build: Easier to handle than MDF molds.
• On-Demand Production: Reduces inventory, streamlining workflow.

With room-temperature vacuum infusion, the 3D-printed mold was not only faster to produce but also more precise and sustainable. Forze IX’s bodywork was shaped using a process that prioritized efficiency, innovation, and environmental responsibility.

A Future Fueled by Innovation

Forze IX is more than a racing car—it’s proof that motorsport can evolve. By replacing outdated manufacturing techniques with advanced digital fabrication, the team isn’t just competing in races; they’re setting a new standard for how racing cars should be built.

Through 3D printing, recycled materials, and automation, Forze Hydrogen Racing has overcome time and cost barriers while making motorsport greener, smarter, and more sustainable.

The company has grown into one of the largest independent composite tooling manufacturers in the UK, specializing in molds and tooling rather than producing composite parts. Traditionally, mold-making required a pattern-first approach, but advancements in large-format additive manufacturing (LFAM) now allow manufacturers to print molds directly, reducing costs and labor while improving efficiency.

As epoxy board costs rise, LFAM offers an economical and sustainable alternative, enabling near-net-shape printing that minimizes material waste. This innovation is particularly valuable in Formula 1 and high-performance industries, where reducing cost and carbon footprints is a priority.

“We have seen about 25-30% reduction of lead time on manufacturing as opposed to the traditional method.” – Kevin Anson, Business Development Manager – Total Machining Solutions

For production fixtures, aluminum and PU boards have been standard, but these materials can be expensive and inefficient, especially for large-scale applications. LFAM solves this by printing only the necessary material, avoiding excessive machining and material loss. As a result, manufacturers experience a 25–30% reduction in lead time compared to conventional methods.

“Because we are printing a near net shape, we are using much less material than we would with clamping PU-boards and machining them to the final shape. It is much more cost effective and quicker.” – Kevin Anson, Business Development Manager – Total Machining Solutions

Material selection is process-driven, with carbon-filled polycarbonate preferred for heated applications like autoclave molds, while PET-G offers a cost-effective solution for room-temperature trim fixtures. The software-hardware integration makes learning and operating the LFAM process seamless, empowering industries beyond automotive and aerospace, such as art, film, and custom manufacturing.

After evaluating different extrusion technologies, the company found CEAD’s industry-leading extruder to be highly reliable and effective, solving many previous challenges. This shift towards innovative, additive-based solutions is helping manufacturers achieve higher precision, reduced waste, and greater cost-efficiency.

Read more about Total Machining Solution’s use of CEAD’s additive manufacturing solutions.

Since 1991, BMW Group has been at the forefront of 3D printing, transforming automotive production. What started with individual vehicle components has evolved into a game-changing process for efficiency, sustainability, and precision.

At the Additive Manufacturing Campus in Oberschleissheim, BMW Group uses advanced technologies to rapidly prototype and manufacture parts with greater flexibility and cost-efficiency. In 2023 alone, over 300,000 components were 3D-printed across its global production network.

How BMW Group uses 3D printing:

• Lightweight Precision Parts: BMW Group engineers optimize designs using topology-based modeling, ensuring parts are structurally sound while reducing weight. This results in bionic robot grippers that are 30% lighter than traditional models, improving speed and energy efficiency.
• Rapid Prototyping & Customization: The ability to quickly print unique, high-performance components enables faster design iterations for race cars, concept vehicles, and production models—minimizing development time.
• Production Aids & Robotics: BMW Group leverages additive manufacturing to create customized work aids and handling tools that streamline manufacturing. For example, in CFRP roof production, 3D-printed grippers reduce robot weight, cutting CO2 emissions while enhancing durability.
• Sustainable Manufacturing: Large-factor additive manufacturing (LFAM) integrates recycled plastics and injection-molded granules, reducing CO2 emissions in robot gripper production by over 60%.

BMW Group continues to push the boundaries of smart, sustainable manufacturing, using additive technology to make production faster, more adaptable, and environmentally responsible.

Efficient Thermoforming with LFAM Technology

This lightweight windshield tool, measuring 900 mm tall and 600 mm wide at just 37 kg, serves as a precision press for shaping PC/PET sheets. It offers an efficient, cost-effective alternative to traditional mold-making by leveraging CEAD’s hybrid Flexbot and Large-Format Additive Manufacturing (LFAM) technology combined with thermoforming.

Compared to labor-intensive and wasteful aluminum or wooden molds, LFAM enables direct mold printing using recycled composite thermoplastics. This approach reduces material use, waste, and lead times while allowing for flexible, simultaneous production of multiple components. The project, developed in collaboration with Jakob Haerting and Severi Salmirinne from REDU, highlights CEAD’s innovative large-format manufacturing capabilities.

Prototype for car door

Prototyping plays a vital role in vehicle development, helping engineers evaluate form, function, and aerodynamics. Traditional methods, using non-recyclable polystyrene (PS) or polyurethane (PU) blocks, are labor-intensive and environmentally harmful—contributing significantly to landfill waste after each testing phase. This becomes especially problematic as automakers face increasing pressure to meet global carbon reduction targets.

Large-Format Additive Manufacturing (LFAM) offers a more sustainable and efficient alternative. Instead of carving prototypes from foam blocks, LFAM prints near-net-shape parts, minimizing material use and waste. Using recycled materials like Airtech’s Dahltram® T-100GF—a co-polyester resin reinforced with fiberglass—LFAM enables faster, more circular production. Its flexible print strategy also allows for the simultaneous manufacturing of multiple parts, cutting lead times and accelerating innovation.

Rethinking Sustainability in Composite Manufacturing

Sustainability is often discussed in manufacturing, but real progress requires rethinking traditional processes. Alan Harper Composites exemplifies this by replacing single-use vacuum infusion materials—like plastic bags and flow mesh—with reusable silicone bagging systems capable of producing 500 to 1,000 parts without generating waste. However, even with reusable bagging, conventional thermoset resin molds remain unsustainable, as they are discarded after each production cycle.

Large-Format Additive Manufacturing (LFAM) offers a transformative solution. For example, in producing a bus engine cover, switching from traditional tooling to LFAM reduced the mold lead time from 60 days to under 7. Printing and machining take less than 24 hours, and finishing is completed within a few days—using recyclable materials and eliminating the need for skilled manual labor or structural reinforcements. LFAM not only accelerates production but also delivers reusable, high-precision molds at comparable costs, proving that sustainable composite manufacturing is not just achievable—it’s the future.

CEAD is a pioneer in Large-Format Additive Manufacturing (LFAM) with a decade of experience, delivering fully integrated, scalable solutions for industrial applications.

CEAD delivers more than just hardware. Its fully integrated systems unite printers, extruders, software, and automation, optimizing workflows for industrial applications. Companies can select turnkey solutions or opt for fully customized systems, ensuring a perfect fit for unique manufacturing requirements.

With a strong presence in automotive, transportation, and motorsports, CEAD’s technology is trusted by industry leaders who require reliability, precision, and efficiency. Headquartered in the Netherlands and offices in the USA. CEAD embodies European engineering excellence, while its global expansion ensures access to advanced manufacturing solutions worldwide.

As industries prioritize sustainability, CEAD supports eco-friendly production practices by integrating sustainable composites into large-format manufacturing. By reducing material waste and optimizing resource efficiency, CEAD helps manufacturers create more responsible, forward-thinking production methods.

CEAD is more than a provider of 3D printing technology—it is a strategic partner in innovation, enabling manufacturers in automotive, transportation, and motorsports to push the limits of performance, efficiency, and sustainability with cutting-edge LFAM solutions.