Three-dimensional printing has rapidly gained traction in the automotive industry, offering significant benefits in terms of design flexibility, production speed, and cost efficiency. However, as the use of 3D printing grows, there is a rising focus on incorporating sustainable materials to minimize the environmental footprint of automotive components. This study centers on using eco-friendly, 3D-printable materials to produce electric vehicle battery covers. The primary goal is to assess these sustainable battery housings’ mechanical properties, durability, and overall feasibility. Additionally, the research explores the potential of foaming polylactic acid filaments in measurement applications using Digital Image Correlation technology, which is widely employed in the automotive sector. The study also evaluates these housings’ manufacturability and real-world applicability, offering insights into their role in the future of automotive production, where sustainability is becoming increasingly important. The research seeks to contribute to the broader movement toward greener manufacturing processes within the automotive industry by conducting these analyses.