The Sintesi is a sports car with four doors and four seats, developed by a highly innovative approach: it does not consider the car as a shape that covers the mechanicals, but one that gives a shape to the mechanicals around the passengers, starting from the latter. This approach, which is known as “Liquid” Packaging, has overturned traditional volumetric balances, improving weight distribution and lowering the centre of gravity, which are important elements for driving dynamics.

Freeform Manufacturing uses additive technologies (also referred to as 3D printing technologies), fully automated processes that don't require molds and thus allow a virtually unlimited freedom in design. Today, these technologies are increasingly used in the production of concept cars. Gradually, this production method will be applied for the production of final cars as well.
The use of Freeform Manufacturing allowed Pininfarina to materialise their creative design ideas. Materialise has produced several components for the Sintesi project, all by means of the additive technology stereolithography: the instrument panel, the radiator, control panels, roof antenna, remote controller and roof light cover.

The interior of the car is not conceived as a separate element but is fully integrated with the overall design. The instrument panel is designed as one integrated semitransparent piece, deriving its richness from a sophisticated play of light that serves as a visual and intuitive feedback for the different functions.
The tremendous complexity of the dashboard combined with the translucent aspect, required the use of additive technologies, as no other technology would have been capable of realizing the same ground-breaking effect. During the file preparation phase, a complex webbing structure was integrated in the dashboard to give it functional strength. The eventual panel was “printed” in its full width on a Materialise Mammoth Stereolithography machine, with a build volume up to 2150 x 700 x 800 mm, in a translucent PP-like epoxy.
Due to its complexity, also the radiator had to be manufactured by means of additive technologies.
The production of the smaller components like the roof antenna and remote controller show the endless personalization possibilities of additive manufacturing. Nowadays, these types of components are already being personalized, by means of additive manufacturing, in small series of production cars or one-offs.