Creating replacement components
Introduction:
Eastbourne Coach Finishers https://www.ecfcarcare.co.uk/ (ECF) provides a range of automotive services including body repair and paint spraying services, specialising in accident repairs for well-known and cherished marques.
Our role:
3D-Consulting (3DC) were hired to provide a replacement part for a Jaguar XK8 in need of repair. The part in question was the passenger’s side bumper to front wing mounting bracket which had been broken.
The pictures below show the passenger side broken (left) and the driver side shown intact (right).
ECF were advised by the OEM that there was a long and indefinite lead time for having the replacement part supplied. This led ECF to consider other supply options. 3DC were able to provide a solution with a quick turnaround involving 3D scanning and 3D printing.
The anticipated time frame from initial 3D scan to delivery of the replacement part was two weeks.
3DC elected to scan the intact bracket on the driver’s side and then mirror the resulting 3D scan to provide a perfect opposing side copy that could be 3D printed to replace the broken bracket.
There were a couple areas that the scanner could not capture and these were 3D modelled in CAD to allow a closed, watertight STL file ready for 3D printing.
For the 3D scanning we used a Creaform Handheld TM portable laser scanner, which provides volumetric accuracy of 0.020 +0.040mm/m. This industry leading scanner would ensure that the replacement part would be a perfect fit.
The resulting 3D printed part was made with FDM (fused deposition modelling) processing using ASA material. This material was because it has similar material properties to moulded ABS plastic. This material choice with its UV-resistance makes it especially suited to production parts for outdoor commercial and infrastructure uses such as automotive.
The two pictures above show (left) 3d printed bracket with the original scanned bracket (right). Below are further close ups showing the precise mount location and vehicle fully repaired.
If you have an urgent parts supply requirement, we can help. 3DC has a wealth of experience in 3D scanning, 3D printing and reverse engineering of components for a wide range of applications. Get in touch to discuss how we can help you with your project.