It sounds like something straight out of science fiction, but it’s now a reality: downloading a car. Driven by passion and ingenuity, Sterling Backus, a physicist and dedicated father, embarked on an extraordinary five-year journey to 3D print a full-scale Lamborghini Aventador. What began as a scaled-down project for his son blossomed into an ambitious endeavor that captivated car enthusiasts and the 3D printing community alike. Backus didn’t just replicate the iconic supercar; he reimagined it, pushing the boundaries of home 3D printing and even earning accolades from Lamborghini themselves.
Front view of the 3D printed Lamborghini Aventador in a garage, showcasing its detailed body and headlight design
The project began humbly, with Backus downloading a 1:10 scale model of the Aventador. Fueled by a desire to create something unique with his son, he decided to scale up the digital blueprint. This wasn’t a mere enlargement; Backus meticulously separated the model into printable parts and even incorporated his own design modifications, most notably widening the car’s body to give it an even more aggressive stance. This customization immediately set his 3d Printed Lamborghini apart, showcasing a blend of replication and personal artistry.
The heart of this ambitious project was surprisingly modest: a Creality Cr 10S, a $350 3D printer often used for hobbyist projects. To realize the full-sized Aventador, Backus ingeniously divided the car’s complex surfaces into manageable one-square-foot sections. These pieces were individually 3D printed and then painstakingly assembled, jigsaw puzzle style, using epoxy to bond them together. This process pushed the limits of the consumer-grade printer, requiring it to run almost continuously for 15 months before it finally succumbed to the relentless workload. Remarkably, by that point, the entire outer body of the 3D printed Lamborghini had taken shape.
Close-up of the 3D printed Lamborghini Aventador's body panels showing the layered 3D printed material before carbon fiber coating
However, using a PLA filament presented a significant challenge. PLA, ideal for smaller models, isn’t designed for the rigors of a full-sized car. Its low glass transition temperature (50-60°C or 131-140°F) meant the 3D printed body was susceptible to warping, especially considering outdoor temperatures and the heat generated by an engine. To overcome this critical limitation, Backus applied a resourceful solution: carbon fiber reinforcement. Each PLA panel was meticulously coated with six layers of carbon fiber sheeting – three on each side. Using vacuum sealing, he ensured a bubble-free and warp-resistant bond. This carbon fiber “sandwich” provided the necessary structural integrity and heat resistance. Following this, each panel underwent extensive sanding after being coated with automotive primer, a process father and son undertook together, ensuring a flawless finish.
Father and son sanding the 3D printed Lamborghini Aventador body panels, preparing them for painting
Word of Backus’s incredible 3D printed Lamborghini project reached the executives at Lamborghini. Impressed by his dedication and craftsmanship, they offered unexpected support. Lamborghini generously donated original Aventador headlights, each costing around $5,000. This single act saved Backus $10,000 and provided authentic components crucial to the car’s realism. While the windshield was cleverly sourced from a Pacifica minivan and trimmed to fit, the taillights presented a different challenge. Due to the widened body, stock Lamborghini taillights wouldn’t fit, so Backus skillfully 3D printed custom taillights, maintaining the car’s unique aesthetic.
Front quarter view of the 3D printed Lamborghini Aventador, highlighting the authentic Lamborghini headlights
Rear view of the 3D printed Lamborghini Aventador, showcasing the custom 3D printed taillights and overall wide-body design
The iconic scissor doors of the Aventador posed another significant hurdle. Even with his physics background, replicating the complex hinges proved exceptionally difficult. Genuine Lamborghini door hinges cost thousands of dollars, adding to the project’s potential expense. Serendipitously, Backus connected with another hobbyist who was also 3D printing an Aventador replica. This fellow enthusiast generously provided spare hinges, demonstrating the supportive spirit within the DIY car building community.
Side view of the 3D printed Lamborghini Aventador with scissor doors open, revealing the interior and door mechanism
What truly sets this 3D printed Lamborghini apart is its ground-up construction. Unlike some replica projects that utilize existing car chassis, Backus fabricated a custom metal chassis from scratch, welding individual pieces to create the car’s structural skeleton. This meticulously crafted chassis then served as the foundation for mounting each 3D printed and carbon fiber-reinforced body panel, resulting in a truly bespoke vehicle.
Close-up of the metal chassis construction underneath the 3D printed Lamborghini Aventador body panels
Interior view of the 3D printed Lamborghini Aventador showing the custom-built metal chassis and cabin framework
Powering this 3D printed marvel is not Lamborghini’s signature V12 engine, which remains beyond the realm of home 3D printing. Instead, Backus opted for a robust LS1 V8 engine from GM, commonly found in Corvettes. Similarly, the transmission is not a Lamborghini component but rather sourced from a Porsche 911, showcasing a pragmatic approach to sourcing functional automotive parts.
Engine bay of the 3D printed Lamborghini Aventador revealing the LS1 V8 engine installation
During a visit to assess the project’s progress, Lamborghini’s director of marketing noticed an Audi steering wheel installed in the dashboard. While Backus pointed out the shared VW ownership of Audi and Lamborghini and the identical steering column, the non-Lamborghini wheel didn’t quite align with brand purism. Shortly after, a genuine Lamborghini steering wheel arrived from Italy, a testament to the brand’s attention to detail and heritage, even for a 3D printed replica.
Interior of the 3D printed Lamborghini Aventador showing the replaced Lamborghini steering wheel
The 3D printed Aventador currently awaits its final paint job, envisioned in a striking red, white, and black scheme. Remarkably, it weighs approximately 2700 lbs, significantly lighter than the original Aventador’s 4000 lbs. Backus is diligently working to complete the exterior finishing touches, fine-tune the electrical systems, and refine the interior, aiming for completion before its public debut. This incredible 3D printed Lamborghini Aventador is scheduled to be showcased at the Bandimere Speedway near Detroit on August 13th, marking the culmination of an extraordinary DIY automotive adventure.
Full side profile of the 3D printed Lamborghini Aventador in a garage setting, showing the overall 완성된 car and its proportions
Sterling Backus’s 3D printed Lamborghini Aventador stands as a testament to the power of creativity, perseverance, and the accessibility of modern 3D printing technology. This ambitious father-son project not only resulted in a stunning, life-sized replica of a dream car but also showcases the potential for customization and innovation within the automotive world, proving that with enough ingenuity, you really can “download a car.”
