Learning Hub - Common Builds

Common Builds

Typical 3D printed automotive parts, settings, and lessons learned.

These examples represent common automotive 3D printing projects seen across the community. Each includes typical settings and practical lessons.

BMW E46 Cup Holder Insert
2003 BMW 325i
Easy
Problem:

OEM cup holder insert cracked, NLA from dealer, eBay prices $80+

PETG (Black)
3 hours
Settings:

4 walls, 50% gyroid, 0.2mm layers

Result:

Perfect fit, 2 years in use, cost $0.50 in material

Lessons Learned:
  • PETG handles coffee cup heat without issue
  • Measured original with calipers before designing
  • Added 0.3mm clearance for snap-fit tabs
Honda Civic HVAC Vent Louver
2008 Honda Civic
Medium
Problem:

Vent louver pivot pin broke, entire vent assembly discontinued

ASA (Gray)
45 minutes
Settings:

5 walls, 60% gyroid, 0.16mm layers

Result:

Functional replacement, matches OEM texture after painting

Lessons Learned:
  • Small parts benefit from finer layer height
  • ASA needed for dashboard heat exposure
  • Texture spray matched OEM grain pattern
Ford F-150 Door Panel Clip Set
2015 Ford F-150
Medium
Problem:

Door panel clips broke during interior work, dealer wanted $8 each

Nylon (PA12)
4 hours (batch of 20)
Settings:

4 walls, 80% gyroid, 0.2mm layers

Result:

20 clips printed for $3 total, stronger than OEM

Lessons Learned:
  • Nylon required dry box during printing
  • Clips need flex - nylon outperforms PETG here
  • Batch printing saved significant time
Porsche 944 Mirror Cap
1987 Porsche 944
Hard
Problem:

Driver mirror cap cracked, no longer manufactured anywhere

ASA (Guards Red matched)
8 hours
Settings:

4 walls, 40% gyroid, 0.12mm layers

Result:

UV stable exterior part, painted to match, 3 years no degradation

Lessons Learned:
  • Fine layers (0.12mm) essential for visible exterior parts
  • ASA critical for UV exposure
  • Automotive 2K clear coat provided paint protection
Toyota Tacoma Glovebox Latch
2012 Toyota Tacoma
Medium
Problem:

Glovebox latch mechanism broke, dealer part $45

PETG (Black)
2.5 hours
Settings:

5 walls, 65% gyroid, 0.2mm layers

Result:

Functional replacement, snap-fit works perfectly

Lessons Learned:
  • High wall count essential for snap mechanisms
  • Test fitted with draft print first (2 walls, 15% infill)
  • Final print used production settings
Mazda Miata Hardtop Seal Clip
1999 Mazda Miata
Easy
Problem:

Hardtop weatherstrip clips brittle with age, breaking during install

TPU 95A
1.5 hours (set of 10)
Settings:

3 walls, 75% gyroid, 0.2mm layers

Result:

Flexible clips that don't crack, improved seal compression

Lessons Learned:
  • TPU adds flexibility that rigid plastics lack
  • Slower print speeds (20mm/s) for TPU
  • No support needed due to simple geometry

Key Lessons Across All Projects

Material Selection
  • PETG for most interior parts - good balance of strength and ease
  • ASA mandatory for any exterior or high-UV application
  • Nylon for clips that need repeated flex cycles
  • TPU for parts requiring elasticity or vibration dampening
Design & Fit
  • Always measure original part with calipers when possible
  • Add 0.2-0.4mm clearance for press fits
  • Test fit with draft print before production settings
  • Use the 3DCarParts measurement tool to verify models
Print Settings
  • Wall count matters more than infill for clips
  • 4 walls minimum for any functional automotive part
  • Fine layers (0.12-0.16mm) for visible exterior parts
  • Gyroid infill for isotropic strength
Post-Processing
  • Texture spray hides layer lines on interior parts
  • SEM Color Coat for factory color matching
  • 2K clear coat essential for exterior paint durability
  • Test finish on scrap before final part

Frequently Asked Questions

Start with a simple interior clip or bracket. Use PETG, 4 walls, 50-60% gyroid infill. Don't try exterior or high-stress parts first. Build confidence with easy wins. See our Getting Started guide for a full beginner roadmap.

First, check printer calibration (print a 20mm cube). Then verify model dimensions with our measurement tool. Adjust tolerances in your slicer or modify the model. Test fits save time.

Yes! We feature community builds with photos and settings. Contact us or share on social media and tag us. Successful prints help everyone learn.

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