Shifting gear into 3D print mode: How Paravan cut production costs by 75% with the BigRep ONE


Vehicle customization company Paravan is a leading international provider of vehicle adaptations for people with a disability or special needs. With their personalized, road-approved, safety-related industrial applications, Paravan doesn’t just deliver car parts from its industrial mobility park in Germany – they offer mobile freedom to those who need it most.

Their solutions are specifically tailored to individual medical needs, incorporating features such as wheelchair access, loading systems, rotating seating, and many more accessibility assets for safety and comfort. Providing such highly tailored automotive components requires a great deal of time consulting, designing, prototyping and installing, to ensure the components work as they should. This makes time and resource savings even more valuable.

BigRep is pleased to be a part of making those savings a reality. Now working with a BigRep ONE, Paravan can rely on large-volume 3D printing technology, instead of depending on older, time-intensive processes to deliver parts.

“With the BigRep ONE, we can quickly and inexpensively print complex components that are either impossible or very difficult to produce by machine,” said Mario Kütt, Head of Mechanical Construction at Paravan, when we spoke with him about how the BigRep ONE is shifting how they produce parts. “Now we print a component that we had previously milled, thereby saving around 75% of the costs.”

In addition to saving 75% on production costs, Paravan is also producing its prototypes almost 50% faster using 3D printing than with traditional methods. One such prototype the Paravan team has printed is a revolutionary new steering mechanism. Unlike in most cars, this Paravan steering wheel is electronic, rather than being directly connected to the steering column. The specialist automotive company designed their own cover for the steering wheel using the BigRep ONE 3D printer.

Custom grips, created from 3D scans, are another example of the kinds of custom parts that Paravan prints with the BigRep ONE large-scale 3D printer. “We have had the printer for a good year, and together with a 3D scanner, our construction engineers work with it daily,” said Alexander Nerz, Paravan’s Head of Marketing & PR. “It’s great to be able to quickly and efficiently build designs overnight... to be able to install the piece into the customer’s vehicle the very next day. It’s a really great tool.”

For more information on how Paravan is using 3D printing to change the way they produce their innovative industrial applications:

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