Reverse engineering a BMW Z4 front bumper intake vent with SHINING 3D and Formlabs
Discover our step-by-step guide to reverse engineering car parts using 3D scanning, 3D printing and post-processing!
Follow the full workflow using 3D scanning to reverse engineer a part, reference planes in Quick Surface, build a parametric model in SOLIDWORKS, and print it on the Formlabs Form 4 3D printer, (including post-processing) to produce a perfectly fitting replacement with similar mechanical properties.
Project Overview:
The project involves a BMW Z4 front bumper intake vent with a broken clip. Due to the complexity of the part, precise measurement with calipers isn’t feasible. Instead, the Shining FreeScan Combo is used for 3D scanning, achieving 20 microns of accuracy. The data is then reverse engineered in SOLIDWORKS and printed using the Formlabs Form 4 resin printer to create a replacement part with similar mechanical properties.
What You’ll See:
- Scanning the Part: Using the Shining FreeScan Combo for high-precision 3D scanning.
- Reverse Engineering in CAD: Creating a parametric model in Solidworks.
- 3D Printing: Comparing Form 3L and Form 4 print times, materials, and build volume.
- Post-Processing: Using the Form Wash and Form Cure for the best results.
- Final Fit: Check out the fit on the BMW Z4.
1. Scanning the Part
The part is scanned with the FreeScan Combo, using a turntable and positioning targets. The scanner offers laser and infrared options; the laser is chosen for high precision. Scanning the targets first, the scanner’s 26 laser lines capture the part’s data, switching to a single laser for hard-to-reach areas. Both sides of the part are scanned, aligned, and merged into a single mesh, exported as an STL file.
2. Reverse Engineering in CAD
In Quick Surface, planes and features are fitted to the mesh for SOLIDWORKS. A parametric model is created in SOLIDWORKS, focusing on surfaces due to the part’s uniform thickness. The model is built and refined to match the original dimensions, then thickened to create a solid body, and exported as an STL file for printing.
3. Loading the Part in PreForm
The STL file is loaded into PreForm, oriented to minimize support material on visible surfaces. The print in Black V5 resin is estimated to take 3 hours and 57 minutes. The Formlabs Form 4’s Low Force Display technology significantly reduces print time compared to the Form 3L.
4. Printing Comparison
Printing the part on both the Form 4 and Form 3L in Tough 2000 Resin highlights the Form 4’s speed advantage. The new V5 resins offer improved material properties, enhancing toughness, stability, and colour accuracy, rivalling injection-moulded parts.
5. Post-Processing
After printing, the part is washed using the new Formlabs Form Wash 2 and cured at 60°C for 15 minutes in the new Fast Cure. Post-curing increases the part’s strength and stability. Supports are then removed from the part.
6. Fitting to the Car
The reverse-engineered part is tested on the car, fitting perfectly and matching the original part, demonstrating the success of the process and the quality of the Black V5 resin.
Featured Products:
SHINING 3D FreeScan Combo 3D Scanner
HYBRID LIGHT SOURCE AND MULTIFUNCTIONAL FEATURES.
- The combination of blue laser and infrared light meets the needs of diverse industries
- Multiple-line mode with 26 or 50 laser lines for overall scans; fine scanning mode for intricate details; infrared light mode for quick scans without markers.
- Achieve industrial-grade accuracy up to 0.02mm
Formlabs Form 4 3D Printer
FAST PRINTING SPEEDS, UNMATCHED ACCURACY.
A cutting-edge masked SLA 3D printer boasting exceptional speed and precision. Utilising Formlabs’ innovative Low Force Display™ Print Engine, it rapidly cures resin layers, ensuring quick and consistent printing, regardless of part complexity or volume.
Experience seamless workflows, unmatched reliability, and superior part quality with the Form 4 ecosystem.
