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With the rapid development of intelligent vehicle technology, traditional vehicle design and manufacturing methods are facing many challenges. Traditional vehicle design and manufacturing methods have problems such as high cost, long development cycle and lack of personalized design. This paper took advantage of the high degree of flexibility, rapid customization and cost savings of 3D printing technology, which can provide entirely new solutions for intelligent vehicle design. This paper mainly analyzed the application of three-dimensional (3D) printing and manufacturing technology in intelligent vehicle design. In intelligent vehicle design, 3D printing can carry out 3D printed body structure design to make parts lightweight. The displacement sensor in the intelligent sensor can measure the displacement, deformation and vibration of the body components, and detect whether the body structure exceeds the safety range, which can provide safety feedback to the owner. 3D printing technology has been involved in automotive dashboard, interior design and customization. In this paper, the effects of vehicles designed under traditional methods and vehicles designed under 3D printing manufacturing technology were compared. The research and development cycle of class A, Class B, Class C and Class D in brand 1 under traditional manufacturing was 3.85 years, 3.13 years, 4.27 years and 4.32 years respectively. The R&D (research and development) cycle of grade A, B, C and D in brand 1 under 3D printing technology was 2.43 years, 2.05 years, 1.64 years and 1.73 years respectively. Under the traditional method, the average R&D cost of different levels of vehicles in brand 1, brand 2 and brand 3 was 191,000 yuan, 20900 yuan and 227,200 yuan respectively. Under 3D printing technology, the average R&D cost of different levels of vehicles in brand 1, brand 2 and brand 3 was 132,600 yuan, 145,300 yuan and 157,500 yuan respectively. The results of this paper emphasize that the application of 3D printing manufacturing technology shortens the development cycle of intelligent vehicles, reduces the development cost, and can be customized, which can be more in line with the needs of users. [ABSTRACT FROM AUTHOR]