Subaru's 3D Printing Tooling Development Case Study

This case study details how Subaru of America, Inc. utilized 3D printing technology to significantly enhance its tooling development process. The Subaru Accessories Product Development (APD) team faced challenges with traditional tooling methods, which were slow and costly. By adopting a large-format Stratasys F770™ 3D printer, the team was able to insource tool fabrication, resulting in a projected cost reduction of approximately 70% and a return on investment within two years. The introduction of a new T25 print head further accelerated the printing process, increasing throughput and reducing tooling development time by over 50%. This shift allowed Subaru to transition from outsourced batch production to an insourced just-in-time manufacturing model, improving operational flexibility. The case study highlights the broader impacts of these changes, including faster response times to urgent tooling requests, reduced waste, and enhanced environmental sustainability efforts, aligning with Subaru's commitment to zero-landfill production practices.