3D Printed Door Panel Light Lenses

General discussion forum. Moderated. Keep it clean and nice folks.
NicolasB
Posts: 261
Joined: Sat Apr 25, 2020 9:27 pm
TOA Membership Number: 0
Years Owned: 1969 Oldsmobile Toronado

3D Printed Door Panel Light Lenses

Postby NicolasB » Sun Dec 13, 2020 2:33 am

So I’ve decided to create my own replacements for my Toronado’s door panel light lenses since one was cracked and the other was just a cheap plastic film. The final version has a couple of imperfections, but it’s normal when the thickness is very small. Overall, I think it came out quite well and should allow more light to pass through compared to my first two prototypes (they were thicker). Plus, this one feels sturdier than the OEM part (less likely to crack). Will update tomorrow morning when the second lens finishes printing and when I test fit/install both of them.
Attachments
CEA72F58-B742-401C-AE7B-0F50EEAD36B2.jpeg
CEA72F58-B742-401C-AE7B-0F50EEAD36B2.jpeg (144.59 KiB) Viewed 16948 times
E60F78F4-75F0-4F0E-A46B-DFADBD9096BA.jpeg
E60F78F4-75F0-4F0E-A46B-DFADBD9096BA.jpeg (331.98 KiB) Viewed 16948 times

User avatar
Otto Skorzeny
Posts: 1721
Joined: Fri Feb 28, 2014 12:41 pm
TOA Membership Number: 0
Years Owned: 1966 Toronado

Re: 3D Printed Door Panel Light Lenses

Postby Otto Skorzeny » Sun Dec 13, 2020 7:45 am

That's pretty cool. You have your own 3D printer?

NicolasB
Posts: 261
Joined: Sat Apr 25, 2020 9:27 pm
TOA Membership Number: 0
Years Owned: 1969 Oldsmobile Toronado

Re: 3D Printed Door Panel Light Lenses

Postby NicolasB » Sun Dec 13, 2020 8:12 am

Yeah! I’m using an Ender 3 Pro. 3D printers are honestly worth the investment for projects like these. For for the courtesy light lenses in the back, they cost almost $30 in Fusick, but can cost significantly less when you make them yourself (1kg roll of filament is between $20-25 on Amazon). On top of that, it will be possible to manufacture parts that are hard or impossible to find.

User avatar
Otto Skorzeny
Posts: 1721
Joined: Fri Feb 28, 2014 12:41 pm
TOA Membership Number: 0
Years Owned: 1966 Toronado

Re: 3D Printed Door Panel Light Lenses

Postby Otto Skorzeny » Sun Dec 13, 2020 9:15 am

How much is the printer?

Do you scan the old part to make the new one or something? What if you don't have an old part? Do you have to build a mockup out of wood or clay?

NicolasB
Posts: 261
Joined: Sat Apr 25, 2020 9:27 pm
TOA Membership Number: 0
Years Owned: 1969 Oldsmobile Toronado

Re: 3D Printed Door Panel Light Lenses

Postby NicolasB » Sun Dec 13, 2020 11:20 am

I believe the printer was $300, but there alternatives that cost less (downside is they can’t make large parts). Now there is a tool that can scan and render parts into a software program (I’m not sure if it can detect actual dimensions), but it could set you back a few hundred dollars the last time I checked for one. What I did was take the original lens out and used a caliper to define the dimensions. I started out with a sketch then created a model in SolidWorks. I’m still not sure what to do in the case of missing parts, but I might create a template or do something similar with the calipers. My dad’s F-85 is missing a pair of back-up light lenses so I might try to eyeball it and use the calipers to measure the size of the socket. After the modeling stage, I usually create prototypes and try to fine tune the part for the best results.

NicolasB
Posts: 261
Joined: Sat Apr 25, 2020 9:27 pm
TOA Membership Number: 0
Years Owned: 1969 Oldsmobile Toronado

Re: 3D Printed Door Panel Light Lenses

Postby NicolasB » Sun Dec 13, 2020 11:22 am

I almost forgot to mention: If you are looking for a 3D printer, buy one that can handle ABS. PLA is another plastic that is used by some for prototypes, but they do not handle the heat very well (will definitely melt in the car on a hot day)

User avatar
Otto Skorzeny
Posts: 1721
Joined: Fri Feb 28, 2014 12:41 pm
TOA Membership Number: 0
Years Owned: 1966 Toronado

Re: 3D Printed Door Panel Light Lenses

Postby Otto Skorzeny » Sun Dec 13, 2020 2:32 pm

So apart from the cost of the printer, how much did your lenses cost each in raw material? Can clear plastic be obtained for back up lenses, etc?

NicolasB
Posts: 261
Joined: Sat Apr 25, 2020 9:27 pm
TOA Membership Number: 0
Years Owned: 1969 Oldsmobile Toronado

Re: 3D Printed Door Panel Light Lenses

Postby NicolasB » Sun Dec 13, 2020 4:24 pm

Yes, the filament comes in many different types and colors, including clear. A rough estimate for the production of the lenses is probably less than $0.75 each (bought 1kg spool for $19.99), which seems like a deal to me compared to $9.50 for an OEM from Fusick.

User avatar
Otto Skorzeny
Posts: 1721
Joined: Fri Feb 28, 2014 12:41 pm
TOA Membership Number: 0
Years Owned: 1966 Toronado

Re: 3D Printed Door Panel Light Lenses

Postby Otto Skorzeny » Sun Dec 13, 2020 5:10 pm

Wow, that's great. Plus you get the satisfaction of doing it yourself. Parts like Fusick's cost so much because the tooling for the injection mold or whatever part is being made used to be very expensive. They have to make up the initial cost in every one they sell.

With 3D printing, IO bet you start seeing the prices for a lot of parts for all kinds of old cars come down. You don't need to contract with a plastic manufacturer in China or wherever to produce 5000 units minimum. An person can make things like this to order.

NicolasB
Posts: 261
Joined: Sat Apr 25, 2020 9:27 pm
TOA Membership Number: 0
Years Owned: 1969 Oldsmobile Toronado

Re: 3D Printed Door Panel Light Lenses

Postby NicolasB » Sun Dec 13, 2020 6:05 pm

Yeah it’s great that 3D printing is becoming common now, it will create more support for classic-even vintage-cars. Hopefully, the next step forward would be affordable 3D printers that can create metal parts. There are several of these machines out on the market, but for a hefty price. I saw one for $75,000 (of course it’s for office use)!


Return to “General Talk”

Who is online

Users browsing this forum: No registered users and 16 guests