How General Motors Scales 3D Printing Tooling With Stratasys

GM engineers at Factory ZERO, Lansing Delta Township, Fort Wayne and Silao explain how Stratasys F900 systems cut tooling cost, remove weeks of lead time and put a proven fix on the shop floor in hours.

$1.4M Annual savings reported at Lansing Delta Township

$1.1M savings reported in five months at Fort Wayne

6 months ROI benchmark cited for capital investment

Scale the solution, not just the part.

GM evaluates additive manufacturing as an operational capability: one that helps plant teams solve problems quickly, then share proven solutions wherever they can create value. By standardizing equipment, materials and design practices, GM can reduce duplicated effort and extend the impact of each validated application.

Lower tooling and replacement-part cost
Reduce the cost of conventional fabrication and external sourcing.

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Faster response to production needs
Move from issue to tested solution in hours or days.

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Safety, quality and continuity
Make lighter tools, protect vehicles and keep production moving.

Production value, made practical.

Each application addresses a specific production need - from cost and lead time to safety, ergonomics and vehicle-quality protection.

91% lower cost | 66% faster lead time

SVCC Lift Assist

Used with a hoist to lift and install a catalytic converter. The conventional tool proposed for the operation was too large for the available space; the additive tool securely holds the component within the working envelope.

Learn about Nylon 12CF

Around $70 vs. $1,000

Liftgate Striker Cover

This magnetic tool holds an SUV liftgate in position while supporting components are installed. It replaces a more costly conventional tool that was more prone to damage.

Learn about F900

Ergonomics + operator protection

Backplate Installation Tool

Magnets locate and align header and backing-plate components during EV battery-pack assembly. The non-conductive handle helps protect the operator from high-voltage cells.

Learn about ASA

Used with a hoist to lift and install a catalytic converter. The conventional tool proposed for the operation was too large for the available space; the additive tool securely holds the component within the working envelope.

Learn about Nylon 12CF

This magnetic tool holds an SUV liftgate in position while supporting components are installed. It replaces a more costly conventional tool that was more prone to damage.

Learn about F900

Magnets locate and align header and backing-plate components during EV battery-pack assembly. The non-conductive handle helps protect the operator from high-voltage cells.

Learn about ASA

My plants have a target: you need a return on investment within six months. We’ve generated that year over year - and we’re on pace to double that this year.

Doneen McDowell | Manufacturing Vice President | Full Size Truck and Large SUV Assembly Operations.

Four plants. One repeatable model.

From local production challenges to shared manufacturing value, the film shows how GM connects practical innovation across the network.

Factory ZERO

Ergonomic production aids, quality protection and 80-90% average savings.

Lansing Delta Township

$1.4 million in reported annual savings through additive applications.

Fort Wayne Assembly

$1.1 million in reported savings in five months from two systems.

Silao, Mexico

Local problem-solving connected to a broader manufacturing capability.

Ergonomic production aids, quality protection and 80-90% average savings.

$1.4 million in reported annual savings through additive applications.

$1.1 million in reported savings in five months from two systems.

Local problem-solving connected to a broader manufacturing capability.

What makes additive tooling viable at GM's scale.

Material: Nylon 12CF replaces metal

35% chopped carbon fiber by weight. Highest stiffness-to-weight ratio in the FDM portfolio. GM uses it where aluminum or steel were previously the only options.

Material: ASA for large-format tooling

UV-stable, durable, and available in multiple colors. GM uses ASA for large hemming tools where weight reduction and fast iteration matter most.

Hardware: F900 production consistency

Precision and repeatability so every part is identical. Large build chamber accommodates full-scale tooling in a single build.

Operations: Spare parts on demand

When a riser breaks, GM manufactures the replacement in-house. No maintenance contracts, no lead times, no inventory of metal spares.

Operations: Iteration without delay

Design changes that would stall a machining pipeline for weeks are produced overnight. Schedule flexibility that conventional tooling methods can't match.

Safety: Better ergonomics, less risk

Lighter tooling eliminates lift assistance. The Equinox hemming tool dropped from 75 lbs to 33 lbs — a direct improvement in operator safety.

35% chopped carbon fiber by weight. Highest stiffness-to-weight ratio in the FDM portfolio. GM uses it where aluminum or steel were previously the only options.

UV-stable, durable, and available in multiple colors. GM uses ASA for large hemming tools where weight reduction and fast iteration matter most.

Precision and repeatability so every part is identical. Large build chamber accommodates full-scale tooling in a single build.

When a riser breaks, GM manufactures the replacement in-house. No maintenance contracts, no lead times, no inventory of metal spares.

Design changes that would stall a machining pipeline for weeks are produced overnight. Schedule flexibility that conventional tooling methods can't match.

Lighter tooling eliminates lift assistance. The Equinox hemming tool dropped from 75 lbs to 33 lbs — a direct improvement in operator safety.

The Stratasys systems GM standardized on.

GM's additive manufacturing infrastructure runs on Stratasys FDM- the industrial platform proven reliable enough to operate as a production standard across 20 plants.

Printer | Stratasys F900

The production-grade FDM system GM standardized across its manufacturing network. Large build chamber for full-scale automotive tooling. Designed for multi-day unattended operation in factory environments.

Material | FDM Nylon 12CF

Carbon-fiber reinforced nylon, 35% fiber by weight. Highest stiffness-to-weight in FDM. Used by GM to replace aluminum and steel conveyor tooling.

Material | FDM ASA

UV-stable thermoplastic for the Equinox hemming tool. Durable for production, light enough to eliminate lift assist, fast enough to iterate in three weeks.

The production-grade FDM system GM standardized across its manufacturing network. Large build chamber for full-scale automotive tooling. Designed for multi-day unattended operation in factory environments.

Carbon-fiber reinforced nylon, 35% fiber by weight. Highest stiffness-to-weight in FDM. Used by GM to replace aluminum and steel conveyor tooling.

UV-stable thermoplastic for the Equinox hemming tool. Durable for production, light enough to eliminate lift assist, fast enough to iterate in three weeks.

Schedule a free factory walkthrough

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A Stratasys additive manufacturing expert will be in touch shortly to learn more about your operation and discuss where additive tooling could reduce cost and lead time, improve ergonomics, and help solve production challenges faster.

Download Automotive Tooling Solution Guide

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How General Motors Scales 3D Printing Tooling With Stratasys

Scale the solution, not just the part.

Production value, made practical.

91% lower cost | 66% faster lead time

Around $70 vs. $1,000

Ergonomics + operator protection

My plants have a target: you need a return on investment within six months. We’ve generated that year over year - and we’re on pace to double that this year.

Four plants. One repeatable model.

Factory ZERO

Lansing Delta Township

Fort Wayne Assembly

Silao, Mexico

What makes additive tooling viable at GM's scale.

Material: Nylon 12CF replaces metal

Material: ASA for large-format tooling

Hardware: F900 production consistency

Operations: Spare parts on demand

Operations: Iteration without delay

Safety: Better ergonomics, less risk

The Stratasys systems GM standardized on.

Printer | Stratasys F900

Material | FDM Nylon 12CF

Material | FDM ASA

Schedule a free factory walkthrough

Find the first applications that can pay back fast?

ebook:

Video:

Automotive Additive Tooling Solution Guide