This is an ongoing project I’ve been working on for a client – he wants a Torana body shell for his Kyosho Mini Z 1/28 scale remote control car.
The process starts fairly simply – find a 3D model of the vehicle in question. Luckily enough, there was a 4 door version available on Thingyverse and appeared to be a 3D laser scan of a scale model. Next it was pulling it into Mesh Mixer for a cleanup; I removed the wheels and a few other minor imperfections from the scan and solidified the model closely followed by a hollow to create an enclosed “shell” of the model, minus the wheels etc. I then created a model of the chassis in Fusion and used this model to cut the base out of the body model. After that, all that was left was to trim the wheel arches and build chassis mountings inside the body.
This is the shell at what I call a draft print stage to double check sizing and clearances, it still needs to be slightly shortened to bring the wheel arches a bit closer together so it sits perfectly over the wheels.
Printing using PETG filament is a Glycol Modified version of Polyethylene Terephthalate (PET), which is commonly used to manufacture water bottles. It is a semi-rigid material with good impact resistance, but it has a slightly softer surface which makes it prone to wear. The material also benefits from great thermal characteristics, allowing the plastic to cool efficiently with almost negligible warpage. There are several variations of this material in the market including PETG, PETE, and PETT.”
This as a draft was printed 0.2mm layer height at around 35mm/sec and is a little rough on the outside due to some infill material getting caught on the nozzle at times – a tweak of the settings for the final print is needed for perfection!