Objective3D Direct Manufacturing has once again demonstrated its unmatched expertise in additive manufacturing solutions through a successful collaboration with Clapson Automotive. Specializing in custom automotive parts, Clapson Automotive approached Objective3D with a unique challenge that underscores the potential and flexibility of 3D printing technologies.
Challenge: Custom Engine Cover Creation
Deric Clapson, the visionary behind Clapson Automotive, needed an engine cover with very specific requirements: a clear, transparent gloss finish made from Polycarbonate material. This was not a standard off-the-shelf item and demanded a bespoke manufacturing solution, leading Clapson to explore the capabilities of additive manufacturing.
Discovery and Selection
Despite being located in non-metro Queensland, Clapson discovered Objective3D, likely through digital platforms such as Google ads. The decision to engage Objective3D was driven by the company’s renowned expertise in 3D printing and scanning technologies, along with its comprehensive CNC machining capabilities.
Solution: A Multifaceted Approach
The project employed a combination of cutting-edge technologies:
3D Scanning: The initial step involved 3D scanning a damaged, non-transparent (dark black) engine cover using the Artec Leo 3D scanner. This allowed for the broken part to be accurately reconstructed and reverse-engineered, producing a .step file for manufacturing.
FDM 3D Printing: To ensure accuracy in fit and dimensions, the part was first printed in FDM Black ASA. This step, although not essential, was requested by Clapson to verify the dimensions on the actual engine before proceeding with the final manufacturing in Polycarbonate.
CNC Machining: Following the successful verification, the engine cover was CNC machined in clear Polycarbonate. It was then subjected to vapour smoothing and polishing to achieve the desired clear, glossy finish.
Experience and Outcomes
The collaboration was characterized by exceptional support and expertise from Objective3D, described by Clapson as “amazing, tremendously great and out of this world.” Despite a challenge related to project timelines due to staff availability, which introduced a slight delay, the final outcome was a testament to the problem-solving capabilities and customer-focused approach of Objective3D.
Impact and Benefits
For Clapson Automotive, the partnership with Objective3D was transformative, enabling the creation of a part that was otherwise unattainable through conventional methods. The project not only illustrated the vast potential of additive manufacturing for custom automotive parts but also highlighted the importance of flexibility, precision, and innovation in addressing unique customer needs.
Conclusion
This case study exemplifies the synergy between Clapson Automotive’s innovative vision and Objective3D’s advanced additive manufacturing capabilities. By harnessing the power of 3D printing, scanning, and CNC machining, Objective3D continues to push the boundaries of what’s possible, delivering tailored solutions that meet the intricate requirements of its clients. This project underscores Objective3D’s commitment to excellence and its pivotal role in driving forward the future of manufacturing in the automotive sector and beyond.
