Originally Posted by
kreb
I can't imagine that this hasn't been discussed here, but can't find the relevant thread, so here goes: Given that a plasma/router table can be made fairly inexpensively (a relative term, of course) If you got a decent Z axis going, say 8 inches or so, why couldn't one print a car body in ABS in 8 inch slices and alignment pegs? A smallish sports car such as the Miata would require a 6' x 14' bed, but if you cut that into 4ths, a 4' x 8' would do it with room to spare. The feed rate would be snail-like by CNC cutting standards, but the upside of that is that there wouldn't be the inaccuracies that you can get with an inexpensive machine running at high speeds. Of course the final surface would lack the smoothness of a stamped metal skin, but a "bondo" like surfacing compound could make short work of that.
What does the brain trust have to say about this? Prototype bodys are generally made either with huge multi-axis milling machines working on a foam block, hydroforming, skill-intensive metal forming or such. 3D printing such a large item would take ages, but a hobbyist with a few months to spare.......