The world of automotive customization is constantly evolving, and at the forefront of this innovation is the application of 3D scanning technology. Projects that showcase the power of clarity and precision are particularly compelling. Take, for instance, the creation of a tube chassis race car using reverse engineering – a process that began with meticulously scanning a wheel fender to design bespoke widebody kits. This innovative approach culminates in a final product expertly inverted and molded on a 3D printed base, demonstrating the transformative potential of 3D scanning for car bodies.
This project, spearheaded by Edward Van Zyl of Dreamworks 3D Printing in Manitoba, Canada, exemplifies the cutting-edge intersection of 3D technology and automotive artistry. As a specialist in both 3D printing and 3D scanning, Edward collaborated with a client driven by the ambition to convert a standard car into a high-performance tube chassis race car. The core of this transformation lay in the precise capture of the car’s existing form using a 3D scanner, specifically to facilitate the design and integration of custom modifications.
Enhancing Car Aesthetics and Performance Through 3D Scanning
“The client’s vision was to enhance his car with a widebody kit,” Edward explained, detailing the project’s genesis. “The owner was intrigued by the possibility of utilizing 3D scanning and 3D printing to bring this vision to life. That’s where we came in.” Dreamworks 3D Printing, always seeking to push boundaries, had recently acquired an EinScan HX, a state-of-the-art 3D scanner intended to tackle ambitious projects just like this car body modification.
The EinScan HX stands out for its ability to handle the complexities of scanning both large objects and intricate details with exceptional precision. Its high resolution and sub-millimeter accuracy are crucial when working with automotive components. Moreover, its capability to effectively scan black and reflective surfaces makes it ideally suited for the automotive industry, where such materials are common. This versatility ensures that whether scanning mechanical parts or entire car bodies, the EinScan HX meets the rigorous demands of automotive 3D scanning applications.
The modification process commenced with 3D scanning the car. Despite initial concerns about the black surfaces posing scanning challenges, Edward and his team found the EinScan HX performed admirably. “To ensure optimal data capture, we applied markers to the car’s surface,” Edward noted. The EinScan HX seamlessly scanned the reflective black surfaces, proving its robustness in real-world automotive scenarios.
Expanding the scope beyond the immediate requirement, Edward added, “We decided to scan the entire car body to test the scanner’s full capabilities, even though our primary focus was the wheel area.” Simultaneously, they also scanned the engine, further demonstrating the scanner’s versatility. “The entire scanning process was remarkably smooth. The EinScan HX excelled at rapidly capturing data, even from large and complex objects like a full car body,” Edward affirmed.
The scan data from both sides of the car body was then imported into Fusion 360 and Blender, powerful software tools for design and modeling. Leveraging the accurate 3D scan of the original bodywork, Edward skillfully designed the widebody kit, extending outwards from the car’s existing form. “Without the precision offered by 3D scanning,” Edward pointed out, “we would have been forced to model everything from scratch. This would have undoubtedly added significant time and complexity to the project.”
The designed widebody parts were then brought to physical reality using 3D printing. After printing, these parts were meticulously assembled and attached to the car body. The car shell, now enhanced with the 3D printed widebody kit, was inverted, and the final body components were crafted from durable fiberglass. This integration of 3D scanning and printing allowed for a precise fit and a custom aesthetic. Beyond aesthetics, the widebody kit serves a functional purpose: by effectively covering the tires, it minimizes turbulence at high speeds and enhances the car’s downforce, contributing to improved handling and performance.
Embracing the Future of Automotive Customization with 3D Scanning
Looking ahead, Edward is enthusiastic about the broader implications of their project. “We plan to showcase this car at upcoming shows, aiming to demonstrate the immense potential of 3D scanning and 3D printing to a wider audience,” he shared. “We believe this methodology is poised to become a cornerstone of race car tuning.” Compared to traditional, often manual methods, utilizing high-precision 3D digital solutions marks a significant advancement in retrofit manufacturing. It facilitates rapid 3D data acquisition, intelligent design iterations, and the efficient production of racing prototypes. This streamlined process translates to substantial savings across assembly, labor, time, and material costs, making 3D scanning a pivotal technology in the future of automotive customization and performance enhancement.
