Scaled, a UK-based technology company has been developing the country’s first 3D printed electric vehicle for a while.

With the goal of bringing large-scale 3D printing technology to production environments across the UK, the engineering team at Scaled is using digital speed to transform large-scale engineering – which ultimately results in geometric freedom, lower costs and increased development time.

The “Project Chameleon” that is drawing our attention today is about building a driving 3D printed vehicle of the same name. The vehicle illustrates another sustainable alternative to driving.

The Chameleon prototype can achieve a top speed of 45 mph, and weighs 150kg in total. Developed in collaboration with the University of Birmingham’s Racing Team, the vehicle features a 3D printed frame produced with high temperature thermoplastics from LEHVOSS as well as a number of non-3D printed parts. To make it as sustainable as possible, they used recycled PA6 as the primary material of the chassis. The strength and durability of this material makes it a good candidate for such automotive component while ensuring circular economy.

Another partner of the project is engineering software company Rafinex that brings its topology optimization software (TO) to fine-tune the final geometry. TO was crucial not only to optimize the design but also to ensure a functional final part in any environment.

As far as additive technologies are concerned, the team uses a manufacturing cell that comprises a large-scale FDM 3D printer and complementary robotics systems.

Scaled is currently working with automotive design customers to help them bypass standard issues such as a long lead-time on part prototypes and high costs. The company is a strong believer of affordable mass customization, which can only be achieved using large-scale 3D printing.

In the meantime, let’s mention that the Chameleon is meant for short-distance travels such as site-patrolling security firms, airport staff, and train station staff. 

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