When Lil Zoomers, a company that specializes in premium electric karts with full-vehicle architectures, approached Colorado-based Cross Industry Dynamics with an idea and a tight timeline, the manufacturer was up for the challenge. The project in question was to turn a concept sketch for a small-scale hypercar into a high-quality prototype within just two weeks so it could be presented at a major automotive trade show in Las Vegas.

Whereas the tight turnaround time for a project of that scale might have scared off other manufacturers, Cross Industry Dynamics, which specializes in LFAM production, believed it could meet the quality requirements and time constraints. In just two weeks, they were proven right. Using Caracol’s robotic LFAM platform the Heron 300 with HV extruders, the Cross Industry Dynamics team was able to directly print the Lil Zoomers prototype, entirely circumventing tooling and mold-making processes.

As Caracol said: “By removing tooling constraints entirely, the design file proceeded directly to production geometry while preserving complete geometric freedom and compressing the manufacturing phase to a fraction of what conventional methods would have demanded.”

In the end, the hypercar’s body and ancillary components were constructed within just 24 hours of continuous print time using a glass-fiber-reinforced PETG. From there, the team was able to dedicate the rest of the two-week lead time to assembling and finishing the components, as well as ensuring the high-quality detailing work needed to impress the trade show attendees. While the hypercar prototype itself is small scale, it does still have a relatively large footprint of 1,643 × 2,895 × 1,402 mm, making the project and timescale all the more impressive.

Ultimately, the Lil Zoomers trade show display piece was completed in the two-week timeframe without having to compromise on the quality or end result. For this type of project, where timing is critical, LFAM can achieve things that conventional production processes simply can’t. As Caracol puts it: “The completed prototype achieved exhibition-ready status within the two-week constraint, demonstrating the practical feasibility of compressing entire product cycles—from conceptual design through fabrication, assembly, and final finishing—into timelines that conventional manufacturing methods cannot support.”

Last year, Cross Industry Dynamics worked on another large-scale project using the Heron LFAM solution: an interactive 3D printed art installation to celebrate Día de los Muertos for the Adams County Festival Latino in Colorado. This installation consisted of two 3D printed skulls, which visitors were invited to paint in honor of departed family members and friends. Caracol’s Heron AM platform is regularly used to directly print large-scale parts that would otherwise have required tooling. For instance, the company recently 3D printed a full-sized sports car roof while reducing its lead time by 40% compared to traditional methods.