3D printed car parts for vintage cars

Can you 3D print car parts?

Yes, 3D printing is a growing manufacturing method and offers both manufacturers and individuals a flexible way to manufacture a range of replacement parts and this is essential when it comes to car parts. It is an efficient method especially for vintage cars where components are difficult to source or are only required in small quantities.

The components needed for classic and vintage cars can be replacement gears, bushes and plain bearings or clips, brackets, screws, handles and housings. 3D printing car parts enables customers to produce functional components tailored to specific vehicle requirements. It is well suited to designing and manufacturing custom parts and low-volume spare parts, offering quick turnarounds without the need for expensive tooling.

As with any manufacturing process, 3D printing may not be suitable for every application, it depends on the specific demands the part needs to meet, and how the part will be used in the vehicle.

igus® can 3D print car parts that are no longer available, provided you have a STEP file for the component.

What automotive parts can be 3D printed?

Component type	Examples
Mechanical components	Guide rings, washers, spacers, rollers
Gears	Worm gears, spur gears, speedometer gears
Interior car parts	Knobs, pedals, head rests, seat mechanisms
Dashboard elements	Instrument mechanisms, bezels, mounts, knobs
Pivot joints	Pedal joints, hand break, bearings and bushings

Customer application of 3D printed car parts for a vintage car

Requirement

In the Stewart Warner speedometer, the gear on the first intermediate shaft which meshes with the worm on the input shaft was no longer in working order. The pinion was no longer engaging with the worm gear. Due to the work done on the speedometer by the previous owner, it was impossible to determine the correct dimensions. The manufacture of a spare part required several attempts and a material that was stable, enabled high precision and was suitable for continuous use.

The speedometer of a Stanley 750B vintage car built in 1924 no longer functioned - the mileage counter was defective. The cause of the defect was found by the owner to be the toothed gear that was located on the first intermediate shaft and meshed with the worm on the input shaft. Due to wear, the pinion was no longer engaging with the worm.

Challenge

What caused the worm gear in the speedometer to become worn?

The problem was caused by the three-section trip meter mechanism: the dials had an axial play of around 0.2mm and there was no spring washer that pressed the dials against each other. Occasionally, a small transfer gear slipped between the dials and blocked the counting mechanism. A slightly curved, 0.1mm-thick brass washer fitted at the side eliminated the axial play so that blockage no longer occurred.

After the cause of the defect had been eliminated, it was possible to set about manufacturing a spare part. With the help of the free CAD software, Dr. Pühler succeeded in creating a CAD file with a 3D model of the component that was needed.

Solution

Several attempts to obtain a functioning spare part

The first order through the igus® 3D printing service was processed without complication and the finished spare part was received after only a few days. The material was stable and even the smallest details were reproduced perfectly. The shaft immediately fitted into the bearings and the worm gear for the output fitted precisely. However, it turned out that the original pinion had become so worn that the estimated dimensions of the gear were too small.

With the igus® 3D printing service, a fully functioning spare part was made from iglidur® I6 material. Due to fast and cost-effective manufacture with the laser sintering method, it was straightforward for the vintage car owner to test several variants of the component in practice. The high-performance polymer ensures the component no longer needs to be lubricated. Even after being in use for more than 2,000 miles, no signs of wear are detectable.

Test of 3D printed spare part: Will it pass the endurance test?

Only one parameter in the CAD model had to be changed, after which the second version was quickly sent for printing. The second specimen also ran well and passed a short endurance test but started to exhibit slight malfunctioning at low revs. A third version with an adapted toothed gear module and helix angle was made which functioned perfectly and engaged correctly.

A big advantage of additive manufacturing is that changes can be implemented quickly and with little effort. The adaptation of the digital model and also the convenient online ordering process and speedy manufacture make it possible to implement adaptations of prototypes and spare parts quickly and cost-effectively.

The difficulty with the manufacture of spare parts by means of 3D printing is often the creation of a suitable 3D model. On the igus® website, there are several free CAD configurators that inexperienced users can utilise for gears, bearings and trapezoidal lead screw nuts.

High quality 3D printed spare parts for vintage cars

After the shaft was thoroughly tested on the test rig, it was fitted into the speedometer, which was installed in the vintage car again. A significant advantage of iglidur i6 is its self-lubricating qualities, meaning the user doesn't have to lubricate the components even if the interacting part is made of metal.

After being in use for more than 2,000 miles, the printed worm gear continues to be in good shape without any obvious signs of wear. The slight traces of metal abrasion that can be seen in the picture come from the driving worm gear and were caused in the starting phase of the test, but they did not change noticeably during further use.

Learn about our testing facilities

3D printed worm gear as a spare part in use in a vintage car

More applications of igus® 3D printing service for automotive parts

Federation of British Historic Vehicle Clubs

igus worked with the Federation of British Historic Vehicle Clubs to demonstrate 3D printing for vintage car parts. When a Stewart Warner speedometer's worm gear failed and original dimensions couldn't be recovered, igus printed a replacement using self-lubricating iglidur i6 material via their 3D printing service. After 2,000+ miles, the part showed no wear.

3D printed components used in racing cars

Inspired by Formula 1, the "Formula Student Germany" design competition pits student teams against each other in open-wheel car races. One of the parts the Formula Student teamneeded to construct its race cars was customised plastic pinions for use as chain tensioners in the chain drive. Unfortunately, special-size pinions have long delivery times, and classic production with milling is time-consuming. The igus 3D printing service quickly assisted, producing the plastic pinions in less than 72 hours.

Further information on 3D printing with igus®

3D printing overview

Learn about our 3D printing processes, customer case studies, design guides and services, and our wear-resistant materials available to buy, including our 3D filaments, resins and SLS powders.

To the 3d printing overview page

CAD database

Explore our CAD database to download ready-made 3D models for our 3D printing materials and components, helping you design and prototype parts faster.

To the CAD database & draw your own part

3D printing service

Our 3D printing service supplies components made from our own wear-resistant plastic with no minimum order quantity. Simply upload your CAD model for instant pricing.

To the 3D printing configurator

Consulting

I look forward to answering your questions

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