In the automotive sector, moving components is a critical process. Engine hoods, windshields and other body parts require dedicated supports that are safe and flexible. However, many industrial transport systems are rigid and poorly suited to ongoing changes in models or production variants.
A major automotive company approached 3DRAP Factory to make the metal carts used to transport and move components within its facilities more efficient.
The initial situation
Until then, the company had used one-piece rubber racks that were long and bulky and commissioned from overseas suppliers. Each rack model required:
- the complete design of the part,
- the creation of a casting resin mold,
- and finally the production and shipping of the component.
This approach meant waiting several months, high design and production costs and limited flexibility: every change or new logistics requirement called for a complete redesign of the system.
A change in approach: the value of modularity
During the analysis and technical consultation stages, the 3DRAP Factory team proposed a new concept: move away from the monolithic rack and adopt a modular approach based on independent, interchangeable inserts.
This approach made it possible to design a custom plug & play solution in which the cart’s metal frame remains unchanged, while the rubber inserts—designed and 3D-printed—can easily be replaced to accommodate components of different shapes and sizes.
Having recognized the potential of this solution, the company decided to completely redesign all the rubber elements on its carts, introducing a fully modular, flexible and reconfigurable system.
The solution developed by 3DRAP Factory
3DRAP Factory created a series of custom rubber inserts compatible with the same metal cart structure.
Each insert has a standardized quick-release fitting, allowing the configuration to be changed quickly without mechanical work on the frame.
In addition, additive manufacturing made it possible to produce the inserts in small batches, eliminating the need for molds altogether and enabling fast reorders, even in limited quantities.
Materials and contact comfort: a “soft touch” effect
To provide maximum protection for the components, the inserts feature a variable-density infill structure:
- the outer surface is soft and flexible, gently cradling the component and absorbing minor impacts;
- the inner core is more rigid, ensuring stability even under heavy loads.
This “soft touch” effect offers the right balance between protection and strength, preventing damage without compromising load capacity or long-term durability.
The results: greater speed, lower costs, maximum flexibility
Adopting the modular solution developed by 3DRAP Factory delivered tangible, immediate results:
- Elimination of mold costs and long waits for production overseas.
- Drastically shorter delivery times thanks to local, on-demand 3D printing.
- Ability to produce small batches, eliminating the need for stock and cutting warehousing costs.
- Immediate adaptability of the cart to new types of components by simply swapping the inserts.
- Greater competitiveness: the company can now quickly reconfigure its carts according to the vehicle model in production, without changing the underlying metal structure.
This project is a concrete example of how the combination of modular design, additive technology and engineering expertise can create a real competitive advantage.
Thanks to the work of 3DRAP Factory, the automotive company gained a more agile, cost-effective and sustainable solution, showing how innovation in the details can turn a simple cart into a strategic production asset.
