We manufacture car spare parts using 3D printing, from individual pieces to small series. The focus is on classic cars, custom conversions, and vehicles for which original parts are simply no longer available.

The most important advantages at a glance:

• Fast availability of rare parts: No waiting for delivery from abroad or endless searching for NOS parts

• No tooling costs: Unlike injection molding, expensive mold costs are eliminated. 3D printing is ideal for small quantities.

• Precise reconstruction: We achieve tolerances in the millimeter range using 3D scanning and 3D design.

• Suitable plastics: UV-resistant materials for outdoor use and temperature-stable solutions for interiors.

• XXL FDM for large body parts: Bumpers, dashboards, and trims in one piece

Together with our customers, we have already implemented concrete projects: a bumper for SSR Performance using XXL-FDM printing, a handlebar fairing for a classic car, and a dashboard for a Pinzgauer. We present these examples in detail in separate sections.

Introduction: 3D Printing for Car Spare Parts

Supply chain problems in the automotive sector are no longer an exception, but everyday. Manufacturers discontinue production for older models, restoration costs increase, and many owners face the problem that their vehicle is no longer roadworthy due to a simple plastic part.

3D printing offers an economic solution here, especially for interior parts, brackets, covers, and body trims. These parts do not fulfill highly safety-relevant functions and can therefore be manufactured quickly and cost-effectively.

This article focuses on 3D printed car spare parts, from modern cars to tuning projects to military vehicles like the Pinzgauer. We work from templates (including defective original parts) or customer drawings, starting from quantity 1.

Which Car Spare Parts Can Be Sensibly Manufactured with 3D Printing?

Not every component is suitable or permissible for 3D printing. However, many interior and body components are ideal candidates.

Interior:

• Covers, panels, brackets

• Ventilation nozzles, dashboard parts

• Gear shift gates, holders for radios, navigation, and displays

Exterior:

• Bumper segments, spoiler extensions, trim strips

• Mirror housings, license plate holders, air ducts

Functional parts (not safety-relevant):

• Clips, snap fasteners, adapters

• Cable holders, sensor holders

Important: Safety-relevant parts such as chassis components, structural crash parts, or brake components should not be printed without manufacturer approval.

3D printing is particularly worthwhile for spare parts that are no longer available (classic cars from the 60s/70s, youngtimers from the 90s), small series tuning parts, and one-off prototypes.

From Defective Part to 3D Model: Data Basis for Printing

The typical workflow is simple: the customer sends the part or a drawing, we take care of digitization and construction, and after approval, printing takes place.

Possible input data:

• Existing 3D file (STEP, STL, OBJ)

• Original part (even broken or worn)

• Simple sketches with dimensions

For physical parts, we use a 3D scanner for high-resolution acquisition. The result is reconstructed into a CAD model via reverse engineering and adapted for printing, taking into account wall thicknesses, tolerances, and reinforcements.

For old or bent parts, several iterations are often necessary. After a trial fit by the customer on the vehicle, we adjust the dimensions until the fit is perfect.

Our 3D Printing Processes for Car Spare Parts

Depending on component size, stress, and surface requirements, we use different 3D printing processes.

FDM (Fused Deposition Modeling): Our main process for car parts. With XXL build volume, we manufacture large, robust 3D printed parts such as bumper segments, air ducts, and prototypes.

Typical materials:

• PETG: Tough and temperature resistant

• ABS/ASA: ASA with UV resistance for outdoor applications

• Carbon-reinforced Nylon (PA12) for temperature ranges up to 150°C

SLS and SLA: These processes are suitable for smaller, complex parts with high detail accuracy, such as buttons, control levers, or delicate brackets. Laser sintering is also useful for special applications.

Post-processing: Sanding, filling, and painting are often crucial for optical integration and everyday quality.

Customer Example 1: XXL-FDM Bumper for SSR Performance

For SSR Performance, we realized a body part using the XXL-FDM process, specifically a bumper element for a performance tuning project.

Initial situation:

• Special body kit design, original bumper not available

• Need for a lightweight, dimensionally stable solution for a prototype

• Small quantity makes injection molding uneconomical

Technical process: The large component dimensions required our XXL-FDM printer. PLA material was sufficient for the prototype for illustrative purposes. Suitable threaded inserts were used for screwing.

What was important:

• Precision and fit to the series bodywork

• Surface quality for paintability in body color

• Weight and stiffness due to internal reinforcing ribs

• Close coordination with the SSR Performance team

Customer Example 2: Handlebar Trim for Classic Car

Handlebar trims in classic cars are often brittle, broken, or completely missing. Spare parts of this type for classic cars have not been available for decades.

The project:

• Classic car from the 1970s

• Old trim heavily damaged, screw mounts broken

• Surface cracked and deformed

Our approach: The customer sent the existing part. We reconstructed the geometry using 3D scanning and reverse engineering. Missing areas were structurally added, known weak points reinforced.

Requirements:

• Original look matching the year of manufacture

• Mechanical stability during driving

• UV resistance to sunlight

• Compatibility with existing mounting points

Customer Example 3: Dashboard for Pinzgauer

The Pinzgauer is an Austrian off-road vehicle designed from the 1970s for military and civilian off-road use. Dashboards of these vehicles crack under decades of stress and are practically unobtainable as replacement parts.

Project starting point:

• Cracked, faded dashboard

• Defective brackets, traces of self-modifications by previous owners

• Goal: Robust and individual dashboard

Technical specifics: The large component required manufacturing in several segments with subsequent joining. Integration of cutouts for original instruments and modern extensions (additional switches, contemporary radio/navigation).

Key aspects of this project:

• Robustness in off-road use (vibrations, dirt, temperature fluctuations)

• Post-paintability

• Precise fit in the cramped interior

Material Selection and Durability: Plastic for Interior and Bodywork

Material selection in the automotive sector is crucial. Parts must withstand temperature fluctuations, UV light, vibrations, and contact with oil or cleaners.

Typical plastics:

• ABS/ASA: Impact-resistant, with good UV resistance, ideal for exterior attachments

• PETG: Tough, temperature-resistant, good for brackets and interior

• TPU: Flexible, for rubber-like components such as bellows or buffers

For each project, we check the specific requirements and select the material accordingly. On request, we can apply paint or color for seamless integration.

With sensible material selection, durability matches the original, often even better, as modern plastics resist wear more effectively.

Steps to Your Own 3D Printed Car Spare Part

The process is deliberately kept simple, for companies, workshops, and hobbyists alike.

Your path to a spare part in five steps:

1. Inquiry and description: Communicate vehicle type, year of manufacture, part position, requirements by email.

2. Data acquisition: Send existing data such as pictures and sketches or the original part by mail.

3. 3D Scan/Construction: We create the 3D model and send a quote with material suggestion and delivery details.

4. Approval and 3D Printing: After your approval, 3D printing and, if necessary, post-processing will be carried out.

5. Shipping: Ready-to-install 3D object with optional installation support (e.g. threaded inserts).

Typical lead times: A few days to a few weeks depending on complexity. Express projects are possible if the vehicle needs to be back on the road quickly.

Legal and Safety-Relevant Information

The 3D printing of car parts is subject to legal frameworks. The reproduction of protected parts may only take place within the framework of applicable laws; trademark and design rights must be considered.

Important to know:

• Safety-relevant components (brakes, load-bearing chassis or crash structures) should only be used with approval.

• Our strength lies in bodywork, interior, brackets, and auxiliary parts.
  

In case of doubt, please contact us in advance; we will be happy to advise you on whether a part can be sensibly realized using 3D printing.

FAQ: Frequently Asked Questions about 3D Printed Car Spare Parts

How long do 3D printed car spare parts last compared to original parts?

Durability depends on material selection, application location, and stress. With sensibly chosen plastic, 3D printed interior parts achieve comparable lifespans to original parts. For outdoor areas, we use UV and temperature-resistant materials like ASA. For extreme loads (e.g., off-road driving), we recommend regular visual inspections.

Can I still use a completely broken part as a template?

Yes, most severely damaged parts can also be digitally recreated using 3D scanning and reconstruction. The prerequisite is that enough geometry is still recognizable. We constructively supplement missing areas; photos, sketches, or dimensions from the vehicle help ensure a perfect fit.

Are 3D printed parts problematic for the TÜV (German MOT)?

Many interior parts and non-safety-relevant trims are uncritical as long as they are properly installed. For safety-relevant or registration-relevant parts (e.g., aerodynamically effective spoilers), coordination with inspection organizations like TÜV or DEKRA may be necessary.

How much does a 3D printed car spare part cost approximately?

The price depends on size, material, complexity, and the effort for 3D scanning/construction. Simple small brackets start in the low double-digit range (€15–50). Complex dashboards or bumpers cost €200–1000+. The 3D printing service is particularly worthwhile for single pieces and small series where injection molding tools would be uneconomical.

Can I reuse the 3D model after printing?

Yes, the once-created model can be used for future reprints, variants, or adaptations. This creates a digital spare parts warehouse without renewed construction costs.

Do you have a missing part? Submit your inquiry now, and we will check for free whether your spare part can be realized using 3D printing. Send us photos or the defective part, and you will receive a non-binding offer including digitization and delivery.

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