When BMW recently unveiled their concept for a 3D printable scale model car, a father and son duo were already miles ahead, working on an even more ambitious project: a full-sized, 3d Printed Car. Sterling Backus, a physicist, and his son have turned their garage into a laboratory, undertaking the incredible task of 3D printing a Lamborghini Aventador. Utilizing desktop 3D printers, they are bringing the dream of a 3d printed car to life, piece by piece, showcasing the impressive capabilities of additive manufacturing.
3D printed Lamborghini
The idea sparked from a desire to demonstrate technology’s potential to his son. Backus wanted to go beyond theoretical discussions and show firsthand what could be achieved with readily available technology. This project exemplifies the evolving landscape of large format 3D printing, taking it from industrial applications to a personal, home-based endeavor. While the automotive industry currently incorporates 3D printing mostly for prototyping and some specialized parts, the Backus project pushes the boundaries, exploring the possibility of creating an entire vehicle using 3D printing technology.
3D printed Lamborghini
For most vehicles today, 3D printed components are minimal, if present at all. Current 3D printing technologies are not yet optimized for mass production of entire car models. However, initiatives like the Lamborghini project are crucial for driving innovation in car manufacturing. Additive manufacturing offers significant advantages, enabling the creation of lighter and optimized components. This leads to improved vehicle performance and reduced production costs through efficient material usage. Sterling Backus’s project embodies this potential, allowing him to achieve his dream of owning a supercar, a 3d printed car version, without the exorbitant price tag of a commercially manufactured model.
Backus, already experienced with 3D printing and various FDM machines, chose the Creality CR-10S, CR-105S, and QIDI Xpro printers for this challenging build. The sheer scale of the project is evident in the material consumption: approximately 220 spools of thermoplastic filaments were used to construct the car’s body. For the body panels, PLA was selected due to its dimensional stability. ASA and ABS filaments were utilized for components like rear light housings and headlights, while carbon fiber-filled nylon provided the necessary strength for interior parts. The journey wasn’t without its setbacks; about 50 spools were dedicated to trials and overcoming printing failures, highlighting the iterative nature of 3D printing and the learning curve involved in creating a 3d printed car.
3D printed Lamborghini
Beyond 3D printing, the construction of this 3d printed car incorporated a range of traditional manufacturing techniques. CNC machining, waterjet cutting, vacuum infusion, and carbon fiber encapsulation were all employed to enhance the vehicle’s structural integrity and aesthetics. Backus explained their approach: “We decided to use advanced technologies to build the car. However, we wanted to use low cost options. This led us to researching different techniques of automobile construction. After choosing to use 3D printing for most of the car body, we needed solidity. Very few choices of heat stress resistant materials were compatible with our 3D printers; so we turned to encapsulation of 3D printed parts with carbon fiber.” This hybrid manufacturing approach demonstrates a resourceful and innovative method to overcome the limitations of solely relying on 3D printing for a project of this magnitude.
3D printed Lamborghini
Sterling intends to showcase his large-scale 3d printed car project, particularly to local schools as a STEM initiative. He aims to inspire young minds in science, technology, engineering, art, and mathematics, recognizing the captivating appeal of a life-size, partially 3D printed Lamborghini. Reflecting on the project’s inception over a year ago, Backus acknowledges the ambitious nature of their undertaking. Investing at least an hour daily and a total of $20,000, a relatively modest sum compared to the $300,000+ price tag of a factory-made Aventador, they have made significant progress. Importantly, Backus clarifies that this 3d printed car is not intended for sale or to compete with Lamborghini. It is a passion project, documented on his Facebook page HERE, meant to inspire and demonstrate the incredible possibilities of 3D printing and personal innovation.
This 3D printed Lamborghini project serves as a powerful testament to the accessibility and potential of 3D printing technology. It underscores how 3D printing is moving beyond industrial applications and empowering individuals to realize ambitious projects in their own homes. While mass-produced 3d printed cars are still on the horizon, the ingenuity and dedication of Sterling and his son offer a glimpse into a future where personalized manufacturing and innovative designs, even for complex products like cars, become increasingly attainable.
