3D Scanning & 3D Printing for Automotive Restoration

CASE STUDY

THE PROBLEM

Our customer came to us with a problem. His 1980s-era Toyota Tercel had rear interior panels that were virtually disintegrating. These parts are no longer available from the manufacturer or from any 3rd party suppliers. He hoped to scan the originals and use the date to 3D print replacement parts.

By reverse engineering the scanned data of the existing damaged part, we produced a brand-new, perfectly fitting replacement part using large-format 3D printing—demonstrating a powerful solution for restoring legacy components with speed, accuracy, and modern manufacturing tools.

Outdated, Damaged, and deteriorating panel needing replacement. This part is no longer manufactured!

Fully restored and perfectly fit part created with NeoMetrix’s unique services and capabilities.

TRADITIONAL METHOD

Without 3D scanning technology, this task is virtually impossible. Maybe some cardboard templates could be manually fit, or hand fitting some ABS sheeting to simply cover the holes.. but the fit and finish would be terrible.

3D Printed in full-scale on the VIIO250 !

NEOMETRIX SOLUTION

The existing parts were carefully prepped using masking tape to hold the disintegrating originals together to the point where they can be 3D scanned. Parts were scanned with the HandyScan Black+ Elite and data exported as an STL file.

The STL file was then imported into Geomagic Wrap in order to fill holes and smooth edges to create a clean and smooth polygon mesh that could then be surfaced. The Exact Surfacing (rapid surfacing) technique was employed in order to create NURBS surfaces suitable for import into CAD. The NURBS surface model was then exported into Geomagic Design X in order to add some vent louvers for air conditioning.

The original panel had a standard, adjustable AC vent, which was no longer present in the panel supplied for scanning. The customer was happy to have fixed louvers in the replacement part. The final surface model, with louvers, was thickened to create a solid model. The solid model was then exported as an STL file and imported in to BigRep Blade for slicing in order to 3D print. The parts were then printed in ProHT material on our BigRep Viio 3D printer, and installed in the car with a perfect fit.

“Exceeded expectations on these rear interior pilar covers for my 1981 Toyota Tercel. As you can tell from the photos there wasn’t much to work with and these guys at NeoMetrix Technologies really came through! The fit was incredible for parts that are nearly impossible to find. Thanks again!” – Steve F.

NEOMETRIX ADVANTAGE

The NeoMetrix process provide quick and accurate data on the existing part, as well as the ability to compensate for missing geometry and facilitate design changes in order to 3D print perfectly fitting replacement parts.

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