Mold-Free 3D Printing of a Full-Size Sports Car Roof

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April 13, 2026 Applications 9874

Caracol, an Italian additive manufacturing company, has successfully produced a full-size sports car roof using its Heron AM robotic platform.

The entire manufacturing process eliminated the need for traditional molds and reduced the lead time by 40% compared to conventional methods.

The roof weighs approximately 30 kilograms and was printed in a single 27-hour session using ABS material reinforced with 20% carbon fiber, extruded through a 5 mm nozzle. The final part is a monolithic structure with no joints or assembly steps, integrating stiffening ribs, localized reinforcements, and trimming reference features directly within the printing process.

After printing, to address the anisotropy inherent in layer‑based manufacturing, the team applied a hand layup of fiberglass to the inner surface and validated material compatibility and adhesion strength through mechanical testing. Subsequent body filler application, painting, and polishing transformed the near‑net‑shape part into an automotive‑grade finish ready for final vehicle installation. Through this hybrid additive manufacturing process combining polymer and composite technologies, the roof achieved mechanical performance comparable to traditional sheet metal solutions.

The project was carried out at the LFAM Center in Turkey. Operating on a microfactory model that supports distributed, on‑demand production, the center features a fully digital workflow from CAD file to finished part. Collaborating with several local enterprises and ES Garaj, Caracol completed this mold‑free production of an automotive‑grade component in just 27 hours, demonstrating the significant potential of large‑format robotic additive manufacturing in the automotive industry.