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As automotive design evolves, enthusiasts and restorers often face a dilemma: how to preserve or personalise their vehicles when specific parts are no longer available—or never existed in the first place. In recent years, 3D printing has emerged as a powerful solution to this problem—particularly for bespoke and cosmetic car parts that go beyond the realm of simple repair.
While many in the 3D printing world focus on functional replacements like clips, buttons, and brackets, there is a growing demand for aesthetic, personalised components that are either impossible to source or don’t yet exist. This case study explores three real-world projects involving the design and fabrication of custom automotive parts using 3D printing: a front badge for an AE Sprinter, custom M3-style lettering for a classic JENSEN C-V8, and a custom housing for a Skoda tweeter sound panel. These projects demonstrate how additive manufacturing is not only keeping vintage and unique cars on the road—but also enabling personalised design and performance upgrades in ways that were once cost-prohibitive or technically impossible.
| Detail | Description |
|---|---|
| Vehicle | Toyota AE Sprinter |
| Part | Custom front badge |
| Techniques | Manual CAD modelling; initial AI-assisted design |
| Materials | ABS filament (black and grey) for UV resistance |
| Printer | Bambu Lab X1C |
| Outcome | Durable two-tone badge restoring and enhancing the car’s identity |
The AE Sprinter is a cult favourite among car enthusiasts. However, sourcing original badging for this vehicle can be an exercise in futility. For one particular client, the front badge was missing and virtually impossible to find. Rather than settle for a generic substitute or leave the space bare, I set out to design and fabricate a bespoke replacement badge from scratch—combining modern manufacturing methods with traditional design techniques.
Initially, I explored using AI design tools to generate the badge from references. While AI produced a few rough concepts, it quickly became clear that achieving the necessary detail, proportions, and authenticity would require manual CAD modelling. The badge had subtle design elements that only a human touch could faithfully recreate.
Once the design was complete, it was printed on a Bambu Lab X1C using ABS filament—chosen specifically for its UV resistance, which is critical for parts exposed to sunlight. The badge was printed in **two colours—black and grey—**using multi-material printing to achieve clean colour separation without the need for post-processing. This not only saved time but resulted in a sharper, more durable finish.
Result: The new badge not only restored the AE Sprinter’s front-end identity but also elevated it with a custom-built, modern take. The client now has a standout emblem that captures both the original design and the precision of modern technology—something that turns heads at every car meet.
| Detail | Description |
|---|---|
| Vehicle | JENSEN C-V8 |
| Part | Reproduction “M3” lettering |
| Techniques | CAD modelling from photo references and measurements |
| Materials | UV-stable resin with chrome-effect paint |
| Extras | Mounting pegs for easy and accurate placement |
| Outcome | Factory-accurate trim restored using modern tools |
The JENSEN C-V8 is an iconic British grand tourer from the 1960s. With so few of these vehicles left, parts are scarce—especially the cosmetic elements like trim lettering. One owner came to me after searching fruitlessly for replacement “M3” script. These seemingly minor details are crucial to the authenticity and visual identity of a classic car.
To recreate the M3 lettering, I worked from photographs and measurements provided by the client. In some cases, this required digitally correcting for distortions or wear in the original samples. Using CAD, I carefully modelled each letter, ensuring the font, spacing, and curvature matched the original design language of the car.
Given that the lettering would be externally mounted, I printed the parts using a tough, UV-stable resin, then applied a chrome-effect paint to replicate the original finish. To simplify installation, I also included mounting pegs on the reverse side to help align the lettering with existing holes or allow for accurate adhesive application.
Result: The client was able to complete the restoration with the historically accurate details that would otherwise have been lost. The final product was indistinguishable from original factory parts, preserving the car’s classic charm with modern precision.
| Detail | Description |
|---|---|
| Vehicle | Skoda (modern) |
| Part | Custom audio tweeter enclosure |
| Techniques | 3D scanning of dashboard + CAD design |
| Materials | Heat-resistant filament with OEM-style matte finish |
| Design Goals | Seamless fit, acoustic performance, no dashboard modification |
| Outcome | Factory-style integration of a premium audio upgrade |
Not all projects involve restoring the past—some are about pushing forward. In the case of a Skoda owner upgrading their in-car audio system, the factory setup lacked the performance they were aiming for. The client had sourced high-end tweeters but needed a custom enclosure that would integrate into the existing dashboard without cutting or compromising any original panels.
To ensure a perfect fit, I began the project by performing a 3D scan of the dashboard area where the housing would be installed. This scan provided accurate geometry of the surface contours, which formed the basis for the CAD design. The goal was to create a discreet but functional tweeter pod that followed the natural lines of the interior and looked like a factory-installed component.
The housing was designed with a focus on acoustic performance, ease of installation, and aesthetic integration. Once finalised, it was printed using a heat-resistant filament suitable for use in automotive interiors. The part was finished with a matte texture to blend seamlessly with the dashboard’s OEM materials.
Result: The client now enjoys a dramatically improved soundstage, with a housing that appears as if it came straight from the manufacturer. This project demonstrates how 3D scanning and additive manufacturing can be combined to deliver upgrades that are both high-performing and visually harmonious with the original design.
These three projects highlight the versatility and creative freedom that 3D printing brings to the automotive space. Each presented a different challenge:
The AE Sprinter badge was about rebuilding lost identity using a combination of hand modelling, AI exploration, and dual-colour printing.
The JENSEN lettering showed how digital craftsmanship can preserve historical accuracy in restoration projects.
The Skoda tweeter housing leveraged 3D scanning and design customisation to improve performance without compromising form.
What connects all three is the craftsmanship and collaboration behind each solution. 3D printing allows for precise control over form, fit, and finish—while giving customers a voice in the design process. Unlike traditional manufacturing, there are no moulds, minimum orders, or long lead times—just a direct path from idea to physical reality.
As 3D printing continues to evolve, the potential for bespoke car parts—especially those involving cosmetic upgrades, personalisation, or obsolete components—will only grow. Whether you’re restoring a rare vehicle, upgrading performance features, or expressing your own design aesthetic, additive manufacturing opens the door to a new level of creativity.
For car lovers, hobbyists, and professionals alike, bespoke 3D printed parts represent a shift—from compromise to customisation.
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