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 Headlight Cover for 1996 Mitsubishi Delica L400
This project focused on designing a custom-fit front headlight cover for a rare 1996 Mitsubishi Delica L400 — a vehicle cherished by enthusiasts but notorious for hard-to-find parts. The client approached ESoliDesign to recreate the cover as a durable 3D-printed replacement that would match the original part’s aesthetics and performance, all while staying within a modest budget.
Delica L400 headlight
Key Challenges & Solutions:
1. No 3D Scan — Only Manual Measurements:
Without access to 3D scanning tools, the entire design relied on careful manual measurements taken directly from the vehicle. This required precision, patience, and iteration to achieve the perfect geometry and mounting fit. ESoliDesign worked closely with the client to double-check dimensions, review photos, and make thoughtful adjustments during prototyping.
2. Material Selection for Real-World Performance:
Since the headlight cover is constantly exposed to high temperatures and UV rays, a generic PLA material wouldn’t suffice. ESoliDesign selected a high-temp UV-resistant ABS filament, ensuring:
- Resistance to heat generated by the light
- Long-term durability in direct sunlight
- A robust, impact-resistant structure
This choice of material extended the functional life of the part and allowed it to be used in real driving conditions without deformation or degradation.
3. Creative Design for Maximum Flexibility:
To accommodate minor inconsistencies in manual measurements and variations in vehicle manufacturing, ESoliDesign engineered the cover with built-in flexibility and multiple fixing points. The final design allowed:
- A secure yet adaptable fit to the housing
- Easy installation by the client
Headlight Cover 3D print
Headlight and Cover
Client Feedback
“ESoliDesign was an absolute pleasure to work with! They helped me design a 3D print project and went above and beyond to ensure everything was perfect. Not only did they fully understand my vision, but also offered insightful suggestions that greatly improved the final design. Their attention to detail and commitment to delivering high quality work was impressive. ESoliDesign was patient, communicative, and truly dedicated to making sure I was happy with the result. I couldn’t have asked for a better experience and highly recommend them for any 3D design needs!”
Whether your project involves full-scale product development or detailed component drawings, ESoliDesign is your trusted partner for precision, innovation, and results. Let’s bring your ideas to life with engineering you can rely on.
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