Client
- Name: Custom project for a private client
- Industry/Field: Automotive Repair
Summary
- Objective: The goal was to design and print a replacement lid to cover the screw holding the door handle of a Hyundai I30, ensuring both durability and aesthetic appeal.
- Inspiration and Concept: The lack of available replacement parts inspired the project. The concept involved reverse engineering the missing lid by taking measurements and photos of the original part from another door.
- Challenges:
- Ensuring the part was strong enough to withstand mechanical stress.
- Balancing the strength of the part with its aesthetic finish.
Photos and Sketches
Car Handle Missing Lid:
Original Lid (Reference):
Final Design:
Production Process
- Materials Used:
- 3D Printing Filament
- Tools and Technologies:
- CAD: Used to create a detailed and precise 3D model.
- Bambu Studio (Slicer): Utilized to optimize the printing process.
- Design Steps:
- Removed the original lid from another door for reference.
- Measured the part using a caliper.
- Took profile photos from two angles.
- Uploaded the photos to CAD.
- Drew the profile shape and adjusted the design based on measurements.
- Iterated through several design improvements.
- Printing Steps:
- Considered the structure of the part to minimize the risk of breakage.
- Adjusted the printing orientation to balance strength and appearance.
- Used supports to achieve a good finish while maintaining strength.
Results and Client Feedback
- Final Outcome: The replacement lid fit perfectly and withstood the mechanical stress it faced during regular use.
- Feedback: Although a personal project, the outcome was highly satisfactory and demonstrated the practical utility of 3D printing in solving everyday problems.
Conclusion and Key Takeaways
- This project presented a unique challenge: creating a durable replacement for a car part that was not readily available on the market.
- Through careful measurement, thoughtful design, and strategic printing orientation, I successfully fabricated a lid that balanced both strength and aesthetic considerations.
- This project enhanced my skills in design optimization and mechanical engineering principles.
- It also illustrated the practical applications of additive manufacturing in automotive repair, highlighting the versatility of 3D printing for personal and professional use.