Toyota has unveiled a high-performance SUV concept featuring 3D-printed components, marking a shift in manufacturing practices.
This concept, based on the Toyota Fortuner and developed by Toyota Customizing & Development (TCD) Asia’s motorsport division, incorporates innovative materials such as 3D-printed parts and Tafnex, a unidirectional carbon fiber-reinforced polypropylene resin sheet.
Materials and Design
The SUV’s front bumper and hood vents are adorned with Tafnex, while direct pellet-fed 3D-printed parts enhance the hood air duct bezels. These materials, developed in collaboration with Japanese firms Mitsui Chemicals and ARRK Corporation, reduce the vehicle’s weight and improve performance. The Hyper-F Concept SUV also features four sport seats, offering a unique user experience compared to traditional two-seater models.
3D Printing
TCD Asia leveraged advanced 3D printing technologies from Mitsui Chemicals and its partners, including the high-speed EXF-12 3D printer from ExtraBold Inc.
This direct pellet-fed 3D printing method uses plastic pellets to form structures, providing benefits over traditional 3D printing by increasing plastic discharge stability and enabling the rapid creation of large parts.
This moldless technique reduces development lead times and initial investment costs, ideal for high-mix, low-volume production. Additionally, it supports sustainable manufacturing by allowing 3D-printed items to be recycled into pellets for future use.
Tafnex Material
Tafnex, created by Mitsui Chemicals, is a lightweight, rigid, and moldable tape with customizable features, suitable for various applications including automobiles and drones. It can reinforce injected or pressed molded parts and be processed into tubes or laminated sheets. Its non-water absorbing properties maintain high bending strength underwater and in high-temperature environments.
These advanced materials and the Hyper-F Concept SUV will be showcased at the Bangsaen Grand Prix 2024 and the Bangkok Auto Salon 2024, highlighting their potential in automotive design and manufacturing.
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