Design World

  • Home
  • Technologies
    • 3D CAD
    • Electronics • electrical
    • Fastening & Joining
    • Factory automation
    • Linear Motion
    • Motion Control
    • Test & Measurement
    • Sensors
    • Fluid power
  • Learn
    • Ebooks / Tech Tips
    • Engineering Week
    • Future of Design Engineering
    • MC² Motion Control Classrooms
    • Podcasts
    • Videos
    • Webinars
  • LEAP AWARDS
  • Leadership
    • 2022 Voting
    • 2021 Winners
  • Design Guide Library
  • Resources
    • 3D Cad Models
      • PARTsolutions
      • TraceParts
    • Digital Issues
      • Design World
      • EE World
    • Women in Engineering
  • Supplier Listings

3D scanning and printing used to retrofit Lotus 340R

By Michael Jermann | November 21, 2014

Share

C.ideasWhile some companies are promising an entire car made of 3D-printed parts, C.ideas, a rapid prototyping company, is using 3D scanning and printing technologies to create and manufacture replacement parts for rare vehicles.

The company used scanning, software and printing products from 3D Systems to produce more than 40 replacement components for a Lotus 340R, a concept car of which only 340 were made in 1998.

“A lot was being written about projects to build an entire 3D-printed car,” said Mike Littrell, founder and president of C.ideas. “But 3D printing an entire car is not a viable solution at this time and is not likely to be for decades. I think the market for replacement components and custom-made items for rare vehicles is an immediate opportunity.”

The company used Geomagic Capture from 3D Systems to capture and process the complex curves and intricate design points of the car. Geomagic Capture brings together a compact, ultra-precise, blue-light LED scanner and software that enables designers to quickly build a 3D model from multiple scans and import it directly into specific CAD applications.

When the Geomagic Capture system arrived, work began immediately. The first scans were of the Lotus’ front hood panel, requiring about 15 to 20 scans to capture.

c.ideas2

The finished car contained more than 40 3D-printed parts, including the hood, fenders and the rear wing of the car.

The finished assemblies created by C.ideas included the front hood, rear deck-lid, fenders and rear wing of the car. The deck-lid was modified after surface capture to include a cold air intake and vents. The wing was expanded to create greater drag at higher speeds. Original fiberglass parts, such as the front hood, were replaced with ABS parts that provide greater flexibility and resistance to cracking. Scans for the trunk were exported to PTC Creo software and sent out for additional design work.

Final models were printed in the materials best suited to meet design, performance and maintenance needs. 3D Systems iPro 8000 systems were used for all the stereolithography parts and the 3D Systems sPro60 HD/HS for the selective laser sintered parts.

c.ideas3

Modeling software allowed designers to add a cold air intake and vents to the original design.

The fenders presented one of the greatest challenges. In the Lotus 340R, they’re free-floating above the wheels, protruding outside the body of the car in a motorcycle-style design, with tight-fitting cutaways to accommodate brake lines, springs and other components.

The dark-colored fenders were spray-painted in white rubber latex to facilitate scanning, after which the rubber was peeled off. Within three or four days, the fenders were recreated, 3D printed in ABS material and mounted.

The Lotus 340R’s washer fluid reservoir and a custom steering-wheel insert were also scanned, modeled and printed. This time, Geomagic Design X software, known for its ability to produce history-based 3D CAD models directly from scans, was incorporated into the process.

c.ideas4

Geomagic Capture, a 3D scanner with integrated processing software, allowed C.ideas to quickly capture part geometry to accelerate modeling and 3D printing.

Geomagic Design X allows users to extract splines directly from the scan data. The software is able to generate feature-based, editable solid models from 3D scans for direct import into SolidWorks, PTC Creo and other CAD packages.

Both the washer-fluid reservoir and the steering wheel insert were printed on a 3D Systems Projet sPro 60 using the lighter, more durable Duraform GF material. The fenders, initially printed in ABS, were also reprinted in Duraform GF.

C.ideas
www.prototype3d.com

3Dsystems
www.3dsystems.com


Filed Under: 3D CAD, TECHNOLOGIES + PRODUCTS, Automotive, ALL INDUSTRIES, Software
Tagged With: 3dsystems, cideas
 

Tell Us What You Think!

Related Articles Read More >

55417-edgeConnectoren_V3.0_05-2022_cmyk_300dpi
edgeConnector product family from Softing now include a REST API
Screenshot 2022-05-10 at 12.00.35 PM
FAULHABER: Everything under control
Rockwell Automation offers new online capabilities with industrial automation software
NYE adds Vishay Miniature Position Sensor to product lineup

DESIGN GUIDE LIBRARY

“motion

Enews Sign Up

Motion Control Classroom

Design World Digital Edition

cover

Browse the most current issue of Design World and back issues in an easy to use high quality format. Clip, share and download with the leading design engineering magazine today.

EDABoard the Forum for Electronics

Top global problem solving EE forum covering Microcontrollers, DSP, Networking, Analog and Digital Design, RF, Power Electronics, PCB Routing and much more

EDABoard: Forum for electronics

Sponsored Content

  • Global supply needs drive increased manufacturing footprint development
  • How to Increase Rotational Capacity for a Retaining Ring
  • Cordis high resolution electronic proportional pressure controls
  • WAGO’s custom designed interface wiring system making industrial applications easier
  • 10 Reasons to Specify Valve Manifolds
  • Case study: How a 3D-printed tool saved thousands of hours and dollars

Design World Podcasts

May 17, 2022
Another view on additive and the aerospace industry
See More >
Engineering Exchange

The Engineering Exchange is a global educational networking community for engineers.

Connect, share, and learn today »

Design World
  • Advertising
  • About us
  • Contact
  • Manage your Design World Subscription
  • Subscribe
  • Design World Digital Network
  • Engineering White Papers
  • LEAP AWARDS

Copyright © 2022 WTWH Media LLC. All Rights Reserved. The material on this site may not be reproduced, distributed, transmitted, cached or otherwise used, except with the prior written permission of WTWH Media
Privacy Policy | Advertising | About Us

Search Design World

  • Home
  • Technologies
    • 3D CAD
    • Electronics • electrical
    • Fastening & Joining
    • Factory automation
    • Linear Motion
    • Motion Control
    • Test & Measurement
    • Sensors
    • Fluid power
  • Learn
    • Ebooks / Tech Tips
    • Engineering Week
    • Future of Design Engineering
    • MC² Motion Control Classrooms
    • Podcasts
    • Videos
    • Webinars
  • LEAP AWARDS
  • Leadership
    • 2022 Voting
    • 2021 Winners
  • Design Guide Library
  • Resources
    • 3D Cad Models
      • PARTsolutions
      • TraceParts
    • Digital Issues
      • Design World
      • EE World
    • Women in Engineering
  • Supplier Listings