Portfolio Details
Project Information
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Client Name: Stephan Moon
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Category: New Product Development, 3D Print
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LOCATION Melbourne
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Custom 3D Printed Part Design for Engineering Applications
At ESoliDesign (ESD), we specialise in custom 3D printed part design for engineering and product development applications.
ESD was engaged to design a custom 3D-printed replacement component for a rare vehicle. The goal was to engineer a precise, durable, and heat-resistant headlight cover that matched the original part’s aesthetics and performance while staying within a modest budget.
This project showcases how our team designed a 3D-printed headlight cover for a rare vehicle — a 1996 Mitsubishi Delica L400 — proving that even without 3D scans, precision engineering and material expertise can deliver production-ready results.
Original headlight assembly used for dimensional assessment
Key Challenges & Engineering Solutions
1️⃣ Manual Measurement Precision (No 3D Scan Available)
Without access to scanning tools, ESD developed this custom 3D printed part design through manual measurement and CAD modelling.
Each dimension was captured directly from the vehicle, double-checked with the client, and iteratively refined until the fit matched perfectly.
This method ensured a precise, manufacturable geometry — achieved entirely through engineering skill and collaboration.
2️⃣ Material Selection for Performance
To ensure long-term performance, ESD selected high-temperature, UV-resistant ABS filament rather than standard PLA.
This engineering-grade material offered:
- Heat resistance under headlight operation
- Long-term durability under UV exposure
- Impact and vibration tolerance for real-world use
The result was a functional 3D printed component capable of matching OEM strength and finish.
Custom 3D-printed headlight cover – functional prototype ready for use
Headlight and Cover
Client Feedback
“ESD was an absolute pleasure to work with! They went above and beyond to ensure every detail was perfect… Their attention to detail, communication, and quality were exceptional. Highly recommended for any 3D design project.”
Outcome
- The custom 3D printed part design process produced:
- Accurate 3D geometry from manual input only
- Heat-resistant, UV-stable prototype ready for installation
- A cost-effective, repeatable design for future reprinting
- A real demonstration of ESD’s engineering-driven product development capabilities
Key Deliverables
- 3D CAD model of the headlight cover
- Prototype development and print validation
- Material performance selection and testing
- Design documentation for re-manufacturing
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At ESoliDesign, we’re here to bring your vision to life. Whether you have a question, need a consultation, or want to discuss your next project, our team is ready to help.
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Contact:
Melbourne, Australia