It's more cost effective to hire a bunch of Cuban machinists to maintain the old cars/build new copies of old cars. If you need to make the project flashy they can get augmented reality welding masks or whatever.

DM(L)S is good for small complicated parts, but for large pieces/large scale manufacturing it's not cost effective (or easy to get the right material properties/do quality control!)

It's the building of new cars that I am after. These cars have been tested in service for 58 years which is more than any other kind of car. Presumably the Cubans have made some modifications and improvements as well.

It's a big idea with a huge addressable market potential-- think every car make going back to the Model T.

Here's an interesting article from the recent Detriot autoshow> http://www.nytimes.com/2015/01/16/business/a-3-d-printed-car...

Probably, but not all of it. You've got engine bearings and cylinder liners with special compounds and tight tolerances.

It might be easier to print forms for pressing/hammering body panels and plugs for molds to cast parts.

I also don't know if I would totally trust a 3d printed frame

Since 3d sintering used metal powder it may be possible to do special alloys as well. I agree that the end solution may be a hybrid one with d printed parts from different materials assembled together.

Also, as you point out a lot of testing would be needed for parts that are exposed to constant stress such as the frame, axles and so on.