Case study

Discontinued spare parts: 3D printing for the automotive sector

A mechanical workshop needed a discontinued part for a limited-edition vehicle. We recreated the wheel arch trim in 3D from scratch, achieving zero-tolerance snap-fit assembly onto the metal bodywork.

3D industrial printing eliminates supply chain dependency

Context

Talleres Chulvi, a specialist high-quality automotive repair workshop, was working on a limited-edition vehicle. This type of client — dealing with special, exclusive or out-of-production vehicles — faces a common problem in the sector: complete dependence on traditional supply chains. Given the very low production volume of the car and its age, original spare parts were simply no longer available.

Challenge

The main challenge was the impossibility of sourcing the part through standard distribution channels. The car could not sit idle in the workshop indefinitely waiting for an untraceable component. The challenge was not purely aesthetic — it was mechanical: we had to recreate an exterior wheel arch trim with a complex curved geometry from scratch, using only the worn original part provided by the workshop as reference. We had to ensure a real snap-fit onto the metal bodywork, with zero tolerance, and a rigidity that would prevent any deformation — something a simple visual design or render cannot achieve.

The outcome

The result was a complete success: the final part was delivered and fitted to the vehicle without any issues or misalignment. Talleres Chulvi was able to complete a repair that would otherwise have been impossible through conventional means.

The project demonstrated that industrial 3D printing can resolve supply chain bottlenecks in the automotive sector — particularly for limited-edition, vintage or out-of-production vehicles — delivering functional, high-precision parts in short timeframes.

Our solution

To tackle the project with maximum precision, we used the original worn part as a physical reference. We carried out a technical 3D modelling process based on direct measurement and geometry reconstruction. The part was printed in industrial-grade PLA+, a material with high structural strength, good dimensional stability and resistance to the mechanical and thermal stresses typical of automotive use.

The design process incorporated snap-fit mounting geometry, calibrated to fit the existing bodywork attachment points. Several iterations were run on critical dimensions before the final production of the part, guaranteeing a reliable, functional result.

Learn more about the case

Can you replicate car parts without an official spare part?

Yes. If an original part exists (even if broken, worn or damaged), we can use it as a physical reference to model it digitally from scratch and manufacture an exact, fully functional replica.

How do you ensure the printed part fits perfectly in the vehicle?

We meticulously validate all measurements and critical points of the component, such as anchoring points, assembly tolerances and joining geometries with the bodywork. For complex projects, we produce a test version first to verify the fit before manufacturing the final part.

What type of automotive parts can you manufacture?

It depends on the intended use and technical requirements. We manufacture components for interior design, supports, housings, guides, mouldings, trims and non-critical functional parts. For parts subject to high temperatures or severe mechanical stress, we define specific technical materials (such as reinforced polymers).

Does 3D scanning make the replication process faster?

Yes. 3D scanning drastically reduces data capture time for the physical part and accelerates the digital modelling phase, making it an indispensable tool for digitising organic surfaces and complex automotive shapes with precision.

Do you also make parts for competition or vehicle customisation?

Yes. We develop fully custom components tailored to each project’s needs: from interior optimisations and technical adaptations to specialised supports and custom components for competition or restoration vehicles.

¿Do you have a project?

If your company is facing a challenge, we would be happy to talk with you and see how we can help.