Introduction
Precision additive manufacturing for legacy automotive innovation. When an automotive client approached 3DX with a unique challenge — retrofitting the instrument cluster of a rare car — traditional manufacturing methods couldn’t deliver the accuracy, speed, or low-volume flexibility the project demanded.
This wasn’t a common mass-production part; it required meticulous detail, robust
performance, and the ability to integrate seamlessly with an aging dashboard layout.
That’s where 3DX’s advanced additive manufacturing capabilities came into play.
- Industry: Automotive Part
- Objective: End Use Part of Instrument Cluster
- Technology: Multi Jet Fusion (MJF) technology
- Material: HP 3D PA-12 Material
Problem Statement
- Replacement parts for rare cars are difficult to source or completely unavailable
- Manual fabrication compromises fit, finish, and durability
- Long lead times and limited scalability make conventional approaches inefficient
3DX Solution
By leveraging high-precision 3D scanning, digital design, and HP’s Multi Jet Fusion (MJF) technology, 3DX developed a fully customized, functional instrument cluster housing in just days. Designed to match the client’s specifications, this part fit perfectly — both technically and aesthetically.
Process
1. Reverse Engineering & 3D Scanning
3DX used Shining 3D scanners to accurately capture the geometry of the dashboard and surrounding components
This data served as the foundation for building an exact digital model
2. Custom CAD Design & Optimization
Using Geomagic Design X and Fusion 360, our design engineers recreated the cluster’s complex geometry
Fit, ergonomics, and visibility were optimized while preserving the original style
3. Additive Manufacturing – Fast, Functional, Repeatable
The cluster was printed using PA 12 material on 3DX’s in-house HP MJF 3D printer
PA 12 was selected for its excellent mechanical properties, ideal for end-use parts in the automotive environment
Within a record turnaround time, 3 fully functional clusters were produced and validated
4. Digital Inventory for Future Production
All design files and print parameters were securely stored
This allows on-demand reprints, ensuring continued support for the rare vehicle without physical inventory
Results
With 3DX’s additive manufacturing solution, the client achieved:
- A perfect-fit retrofit part with high strength and dimensional accuracy
- Fast turnaround without compromising performance
- Future-proofing through a digital inventory ready for instant reproduction
At 3DX, we help automotive innovators keep rare vehicles alive — one precision part at a time.