DBO - Design Build Optimise
Design, Fabrication and 3D printing by Rushil Kisoon
๐๐๐๐๐ผ๐บ ๐ง๐ผ๐๐ผ๐๐ฎ ๐๐ผ๐ฟ๐ผ๐น๐น๐ฎ ๐ฅ๐ซ๐ถ ๐๐ฟ๐ถ๐น๐น๐ฒ ๐๐ฎ๐ฑ๐ด๐ฒ
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I was recently requested to create a grille badge for a Toyota Corolla RXi.
It makes use of a hidden sandwich plate mount. This allows the badge to fit perfectly between the grille slots whilst still being securely fastened with two screws.
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Printer: Ender 5 Pro
Filament: CCTREE PETG Black, PLA Red, PLA Silver
Nozzle: 0.4
Layer Height: 0.12
Slicer: Cura 5
Link:
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๐๐ผ๐ฟ๐ผ๐น๐น๐ฎ ๐๐ผ๐ผ๐ ๐ฆ๐ฝ๐ผ๐ถ๐น๐ฒ๐ฟ ๐๐ฟ๐ฎ๐ธ๐ฒ ๐๐ถ๐ด๐ต๐ ๐๐๐ ๐ฅ๐ฒ๐ฝ๐น๐ฎ๐ฐ๐ฒ๐บ๐ฒ๐ป๐
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After 20 years of use, some of the brake light LEDs failed, whilst others lost significant brightness.
New brake light assemblies were far too expensive when the only issue were the LEDs.
Each resistor and LED was replaced and soldered to restore the original brightness of the brake light.
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Being able to reproduce rare and out of production car parts is one of the main upsides to 3D printingโฆ The satisfaction when a part as complex as this, lines up and clips in, is incomparable.
๐ฆ๐ฒ๐น๐ณ-๐๐ฒ๐๐ฒ๐น๐น๐ถ๐ป๐ด / ๐๐น๐ผ๐ฎ๐๐ถ๐ป๐ด ๐ช๐ต๐ฒ๐ฒ๐น ๐๐ฒ๐ป๐๐ฟ๐ฒ ๐๐ฎ๐ฝโโโโโโโโโโโโโโโโโโโโโโโโ
I didnโt like the look of the included centre caps, so I decided to make new ones. The plan was to just have a Toyota logo, but after finding a fidget spinner in my room, the idea slowly developed into the Rolls Royce style cap, which has a weighted, self-levelling, logo.
The design process involved a few iterations, since the tolerances were so fine. The final assembly consisted of 6 parts. The centre cap, the new spinning cap, the logo, a bearing, the bearing mount and the bearing cover.
The central hole of the included cap was used to mount the bearing holder, with some epoxy, whilst allowing the shaft of the cap to pass through.
606 ZZ bearings were used, but after some initial testing the grease within them proved to be too viscous to allow the cap to spin freely. Subsequently the grease was removed and replaced with a coating of Q5 graphite spray.
Improvements can be made, such as the use of sealed or ceramic bearings, but as a proof of concept, the idea seems to work well.
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Printer: Ender 5 Pro
Filament: CCTREE PETG Black, PLA Gold
Nozzle: 0.4
Layer Height: 0.12
Slicer: Cura 5
Link: https://www.thingiverse.com/thing:5446290
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๐ง๐ผ๐๐ผ๐๐ฎ ๐ฃ๐ฎ๐ป๐ฒ๐น ๐๐น๐ถ๐ฝ: ๐ต๐ฌ๐ฐ๐ฒ๐ณ-๐ฌ๐ณ๐ฎ๐ญ๐ญ
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These panel clips are almost designed to fail upon removalโฆ So instead of purchasing new ones with the same weak points, redesigning them in SolidWorks allowed for improvements to be made.
Various iterations were designed and tested for strength and durability, before being printed in PETG.
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Printer: Ender 5 Pro
Filament: CCTREE PETG Black
Nozzle: 0.4
Layer Height: 0.12
Slicer: Cura 4.13
Link:
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๐ง๐ผ๐๐ผ๐๐ฎ ๐ฆ๐๐ฒ๐ฒ๐ฟ๐ถ๐ป๐ด ๐ช๐ต๐ฒ๐ฒ๐น ๐๐บ๐ฏ๐น๐ฒ๐บ/๐๐ผ๐ด๐ผ/๐๐ฎ๐ฑ๐ด๐ฒ โโโ
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This style of Toyota steering wheel has the logo printed onto a metal disk, possibly through dye sublimation.
After years of use, the dye wears away, revealing the shiny metal underneath.
Since the badge is part of the airbag assembly, it is not sold separately. Subsequently, a 40 mm logo was designed and printed to fit over the worn part.
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Printer: Ender 5 Pro
Filament: CCTREE PLA Black and Silver
Nozzle: 0.4
Layer Height: 0.16
Slicer: Cura 4.13
Link:
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๐๐ผ๐ฟ๐ผ๐น๐น๐ฎ ๐๐ง ๐๐๐ ๐๐บ๐ฏ๐น๐ฒ๐บ๐
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The Corolla and GT JDM style badges were recreated to add an OEM touch.
The original gel sticker emblems that came on models were underwhelming when compared to proper 3-dimensional emblems.
They were printed in various colours and adhered to the rear boot lid, as well as the front fenders, as originally intended.
Part numbers:
75442-1A370
75351-12060
75444-1A440
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Printer: Ender 5 Pro
Filament: CCTREE PLA Gold, Silver & Black
Nozzle: 0.4
Layer Height: 0.16
Slicer: Cura 4.11
Link:
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๐๐ผ๐ฟ๐ผ๐น๐น๐ฎ ๐๐ง ๐๐๐ ๐๐บ๐ฏ๐น๐ฒ๐บ๐
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The JDM style Corolla and GT badges were recreated to add an OEM touch.
The original gel sticker emblems that came on models were underwhelming when compared to proper 3-dimensional emblems.
They were printed in various colours and adhered to the rear boot lid, as well as the front fenders, as originally intended.
Part numbers:
75442-1A370
75351-12060
75444-1A440
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Printer: Ender 5 Pro
Filament: CCTREE PLA Gold, Silver & Black
Nozzle: 0.4
Layer Height: 0.16
Slicer: Cura 4.11
Link:
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๐๐ ๐ช ๐ญ๐ฐ ๐๐ฎ๐ต ๐ฅ๐ฒ๐ฎ๐ฟ ๐๐บ๐ฏ๐น๐ฒ๐บ โโโ
๐๐ ๐ช ๐ฃ๐๐
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The new G29 Z4 rear emblem is much more modern looking than the previous generations.
The emblem was modelled and printed for , finished in gloss black.
A set of PDC blanks were also created, which clip into the OEM mounting brackets.
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Printer: Ender 5 Pro
Filament: CCTREE PLA
Nozzle: 0.4
Layer Height: 0.12
Slicer: Cura 4.13
Link:
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๐๐๐ฒ๐น ๐๐ฎ๐ฝ ๐๐ผ๐น๐ฑ๐ฒ๐ฟ - ๐๐๐ญ๐ญ๐ญ ๐๐ผ๐ฟ๐ผ๐น๐น๐ฎ โโโ
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I was always curious as to why there was a notch in the fuel doorโฆ turns out that it is the perfect place to mount a petrol cap holder.
The best part, it fits perfectly in the gap when the door is closed.
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๐ฉ๐ฎ๐น๐๐ฒ ๐ฆ๐๐ฒ๐บ ๐๐ฎ๐ฝ
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The old valve stem caps were cracked and lost their threads. Instead of replacing it with the standard style, a set of caps with the Toyota logo were printed out.
A layer change was done before the logo, allowing a contrasting colour to be seen, in this case, gold.
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Printer: Ender 5 Pro
Filament: CCTREE PLA - Black & Gold
Nozzle: 0.4
Layer Height: 0.16
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๐๐ผ๐ฟ๐ผ๐น๐น๐ฎ ๐ฅ๐ฒ๐บ๐ผ๐๐ฒ ๐๐๐๐๐ผ๐ป ๐ฅ๐ฒ๐ฝ๐น๐ฎ๐ฐ๐ฒ๐บ๐ฒ๐ป๐
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Many years of wear and tear have deteriorated the button on the remote for the alarm.
This part is long out of production, so I decided to recreate it using TPU.
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Printer: Ender 5 Pro
Filament: CCTREE TPU
Nozzle: 0.4
Layer Height: 0.12
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๐๐ฟ๐ผ๐ป ๐ ๐ฎ๐ป, ๐ฃ๐ฎ๐น๐น๐ฎ๐ฑ๐ถ๐๐บ ๐๐ฟ๐ฐ ๐ฅ๐ฒ๐ฎ๐ฐ๐๐ผ๐ฟ ๐ ๐ฎ๐ฟ๐ธ ๐
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โโโ Swipe to power down.
The instantly recognisable arc reactor from Iron Man 1.
A mixture of white and blue LEDs, created the cyan hue, whilst being powered by USB.
Copper wire wound around the outer ring completes the Industrial look.
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Printer: Ender 5 Pro
Filament: CCTREE ABS, PLA
Nozzle: 0.4
Layer Height: 0.2
Slicer: Cura 4.11
Link: thing:2069812
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๐ฆ๐ฒ๐ฐ๐ผ๐ป๐ฑ๐ฎ๐ฟ๐ ๐ฃ๐ฎ๐ฟ๐ธ ๐๐ถ๐ด๐ต๐ ๐๐๐น๐ฏ ๐๐ผ๐น๐ฑ๐ฒ๐ฟ - ๐๐๐ญ๐ญ๐ญ ๐๐ผ๐ฟ๐ผ๐น๐น๐ฎ
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DesIgn and fabrication of bulb holders for .rolla
Adding the extra park light bulb both completes the JDM look, as well as improves on safety. Since the lights were designed for this feature, but was not included on South African models, it was a simple retrofit.
PETG was used to ensure that the holder was able to maintain its form despite the heat from the bulb.
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Printer: Ender 5 Pro
Filament: CCTREE PETG - Black
Nozzle: 0.4
Layer Height: 0.2
Slicer: Cura 4.8
Link:
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๐๐๐ฒ๐น ๐๐ฎ๐ฝ ๐๐ผ๐น๐ฑ๐ฒ๐ฟ - ๐๐๐ญ๐ญ๐ญ ๐๐ผ๐ฟ๐ผ๐น๐น๐ฎ โโโ
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Some close up pictures of the fuel cap holder from the previous post. rolla
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Printer: Ender 5 Pro
Filament: CCTREE PLA - Black
Nozzle: 0.4
Layer Height: 0.2
Slicer: Cura 4.8
Link:
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