3D Printing Muscle Car Parts | Equus Case Study

The New American Muscle Car

After re-locating to Michigan in 2011, Equus Automotive teamed up with Stratasys Direct Manufacturing to aid in the manufacturing of the prototype/pre-production BASS770. Equus’ model 770 defines a new iconic American muscle car. Beneath its brilliant exterior lies an amalgam of advanced manufacturing, including 3D Printing and cast urethanes. Stratasys Direct Manufacturing's Stereolithography (SL), Fused Deposition Modeling (FDM), Laser Sintering (LS) and cast urethanes were used to build multiple interior and exterior components including the instrument panel, headlight and taillight bezels, HVAC ducting, glass trim panel fender, console covers, seat belt covers, under hood components, and more.

The majority of the components Stratasys Direct Manufacturing 3D Printed were used as master patterns for casting. Cast urethanes are an economical alternative to injection molding for projects requiring low volumes of parts. Cast urethanes begin with a 3D Printed or CNC’d master pattern. Once Stratasys Direct Manufacturing creates master patterns, the parts are treated to post-processing to achieve the desired surface finish. Then a silicone mold is formed around the master pattern. The mold is then cast with advanced polymer urethanes, revealing strong pre-production parts. The casted components were assembled onto Equus’ BASS770 after further finishing.

Not all 3D Printed parts were used as master patterns; some components were 3D printed and then chromed or simply assembled on the car after post-processing. “We did the grille in FDM,” says Jordan Golden, Project Engineer at Stratasys Direct Manufacturing. “Equus used the grille for form, fit and aesthetic checks on their prototype model. We also created LS pieces that Equus chromed and used as different levers for seat adjustment.”

Other 3D printed components were spin casted, such as the chrome lettering on the car. Many of the cast urethane components in the interior are leather wrapped. Stratasys Direct Manufacturing was thrilled to be included in the prototyping of such a spectacular car; the designers, engineers, modelers and builders that compose the genius team at Equus Automotives expanded the horizons of Stratasys Direct Manufacturing technologies.

This car is not just a nod to the iconic muscle cars of the 60s and 70s, but a burst of fresh manufacturing power into an at times stagnant industry. Equus showcases a firm hold on advanced technologies by coupling traditional cast urethanes with 3D Printing and the innovation to move a niche industry of American luxury vehicles forward.

What’s perhaps the main attraction of cast urethanes and 3D Printing for a luxury vehicle with 640 HP and a LS9 Supercharged 6.2L engine? Rudimentary: Optimum customization and full control of details with complete manufacturing done in the United States.