Canada Unveils Two 3D-Printed Electric Vehicles with AI-Designed Chassis

Canadian Innovation Takes the Wheel

Canada's Automotive Parts Manufacturers' Association (APMA) has unveiled two groundbreaking electric vehicle prototypes under Project Arrow Phase 2.0 at the 2026 Canadian International AutoShow in Toronto. What makes these vehicles remarkable isn't just their performance specs — it's how they were built: both feature chassis created using artificial intelligence and 3D printing.

The Vector: Sporty Crossover with Serious Power

The Project Arrow Vector is the more conventional of the two prototypes, taking the form of a dramatic sporty crossover that builds upon the original 2023 Project Arrow concept.

Key specifications:

• Power: 650 horsepower (up from 550 hp in the original)
• Range: Approximately 550 km (341 miles)
• Autonomy: Level 3 self-driving capability
• Chassis: AI-designed, 3D-printed blend of aluminum and polymer

The design is striking — almost as dramatic as some of the wildest concept cars from major manufacturers, yet this is a fully Canadian effort.

The Borealis: Autonomous Shuttle of the Future

The Borealis takes a different approach entirely. This Level 5 autonomous vehicle has no pedals and no steering wheel — it's designed for fully self-driving operation.

Key specifications:

• Range: Target of approximately 1,500 km
• Autonomy: Level 5 (fully autonomous)
• Design: Shuttle-style vehicle for urban mobility
• Connectivity: Vehicle-to-vehicle and vehicle-to-infrastructure communication

3D Printing at the Core

What sets both vehicles apart from traditional EV development is the manufacturing approach. The chassis for both the Vector and Borealis were designed using artificial intelligence and then fabricated through 3D printing with a combination of polymers and aluminum.

This approach offers several advantages:

• Rapid prototyping: Design iterations can be printed and tested quickly
• Weight optimization: AI can design structures that use material only where needed
• Complex geometries: 3D printing enables shapes impossible with traditional manufacturing
• Local production: Components can be manufactured closer to assembly points

All-Canadian Supply Chain

Project Arrow is a showcase for Canada's automotive supply chain capabilities. Both vehicles are Canadian-designed, Canadian-engineered, and Canadian-built, drawing on more than 80 suppliers and partners across the country.

Ontario Tech University serves as the main construction partner, supporting technical integration, prototype assembly, and advanced research collaboration.

From Concept to Production Path

The original Project Arrow concept from 2023 demonstrated what was possible. Phase 2.0 takes it further by showing a path toward commercial viability.

The Vector, positioned as the "near-term innovation platform," is designed to demonstrate commercially viable Canadian technologies aligned with the expected 2030 mobility landscape.

The Borealis explores further-future concepts for fully autonomous urban transportation.

Why This Matters for 3D Printing

The use of 3D printing for vehicle chassis is still relatively rare in the automotive industry. Most manufacturers use AM for prototyping, tooling, or small interior components. Building structural chassis elements through additive manufacturing at this scale represents a significant step forward.

It demonstrates that:

• 3D-printed structural components can meet automotive safety and performance requirements
• AI-assisted design combined with AM can accelerate vehicle development
• Smaller manufacturing nations can compete by embracing advanced manufacturing technologies

The Numbers Behind Project Arrow 1.0

The original Project Arrow demonstrated impressive results:

• $20 million project cost
• $500 million in project benefits
• 25 technology innovations
• 534 RFP responses
• 60 partners and suppliers
• 5 countries visited

What's Next

Project Arrow 2.0 continues to accept proposals from companies wanting to participate. The initiative serves as both a technology demonstrator and a business development tool for Canadian automotive suppliers looking to showcase their capabilities to global OEMs.

For the 3D printing industry, this project provides a compelling case study in how additive manufacturing can scale from prototyping to structural vehicle components — potentially pointing toward a future where more vehicles incorporate 3D-printed elements in their core structure.