The 2025 Additive Manufacturing User Group (AMUG) conference

The 2025 Additive Manufacturing User Group (AMUG) conference is about to kick off: the perfect combination of automotive and additive manufacturing

The Additive Manufacturing User Group (AMUG) meeting for 2025 is scheduled to be held in Chicago, Illinois, USA, from March 30 to April 3, 2025 local time. This is an important event that brings together experts, scholars, and industry leaders in the global additive manufacturing field to discuss and share the latest developments, application cases, and future trends in 3D printing technology.

Joe Scarbo is about to step onto the AMUG conference stage to share his experience in the integration of racing engineering and cutting-edge manufacturing technology throughout his career. Scarbo’s career began with his love for cars and remote-controlled cars. He was a “mechanical maniac” since childhood, obsessed with dismantling toy cars and reassembling them, and also developed a strong interest in automotive sports. This passion drove him to study mechanical engineering at California State Institute of Technology Pomona and eventually became the chief chassis and suspension engineer for off-road racing projects at Volkswagen’s sports division.

 

Discovering the infinite potential of 3D printing

During this period, Scarbo accumulated rich practical experience and worked at a 3D printing service bureau. There, Scarbo first realized the enormous potential of this technology, especially after advances in materials science and manufacturing processes, where 3D printing gradually became a viable and powerful manufacturing tool. He recalled, ‘At that time, I learned about different manufacturing processes, how to use them, and what to expect from materials.’ At that time, materials were limited, but now technology has developed to the point where 3D printed parts can be practically used in the long run.

Scarbo’s latest masterpiece, the SV Rover, is the world’s first legally driven “super truck”. This model not only showcases the perfect combination of extreme off-road capability and high-performance engineering, but also highlights the key role of additive manufacturing in modern vehicle design. The SV Rover offers the option of a 1100 horsepower turbocharged V8 or a 1000 horsepower electric power system, with many 3D printed components integrated into its construction, such as stainless steel exhaust manifolds, complex suspension components, and aerodynamic elements. The design complexity of these components is extremely high, including internal cavities that are difficult to implement using traditional methods.

Scarbo successfully completed the Baha 1000 endurance race using 3D printed carbon filled nylon parts, proving the durability and reliability of 3D printed parts. By using 3D printing technology, Scarbo is able to design and produce with flexibility that traditional manufacturing cannot possess. For example, in the door components designed for an off-road truck, except for the original Land Rover door handles, the remaining components are all manufactured by the company itself, including SLS aluminum 3D printed hinges and carbon fiber exterior door panels. The car is equipped with a complex set of network components, including OEM lock devices, OEM window adjusters, and customized integrated speaker grilles. The speaker grille adopts SAF printing technology and is optimized for specific drivers. The FDM process allows for the construction of a completely sealed cavity inside the car door, providing ideal space for sound performance. If traditional manufacturing methods are used, such a design is almost impossible to achieve.

For Scarbo, 3D printing is not only an indispensable part of the racing development process, but also plays a revolutionary role in prototype design and small batch production. Although 3D printing is not suitable for all scenarios, it performs exceptionally well in applications that handle complex geometries and small batch production, such as custom exhaust systems and suspension components. In addition, with the increasing demand for customized automotive components in the market, 3D printing provides fast iteration and low-cost solutions, particularly suitable for the needs of the aftermarket.

look into the future

At the AMUG 2025 conference, Scarbo will provide a detailed account of his exploration in the field of 3D printing and its impact on the future automotive industry. Whether it’s racing challenges on the track, extreme off-road in the desert, or daily driving on city streets, additive manufacturing has become an indispensable part of modern vehicle design. For the audience attending AMUG 2025, this is undoubtedly an opportunity to gain a deeper understanding of how 3D printing is reshaping modern vehicle design concepts. Let’s look forward to Scarbo’s wonderful speech together!

Regarding Scarbo Performance

Scarbo Performance was founded by Joe Scarbo in September 2008 as a design and manufacturing company that utilizes modern tools to produce competitive products. Its innovative design methods have been fully reflected in every product developed!