Hey there! Witnessing the incredible utility and surprising resilience of 3D printed components firsthand has been a game-changer in my automotive repair journey. I’ve recently embarked on designing and creating replacement parts for my 2005 Smart car, starting with a crucial element: the driver’s side wiper bushing/retainer.
While still under rigorous testing to ensure ultimate robustness, the initial PETG print of this part is performing exceptionally well. It’s even arguably over-engineered compared to the original part! The remarkable printability and strength of plastic threads are particularly noteworthy. Coupled with newly 3D printed TPU wiper gaskets to replace the deteriorated originals, the entire wiper assembly is functioning flawlessly. For enhanced durability and longevity, I plan to reprint these components in CF-Nylon, making them truly reliable for extended use.
Acquired from Ottawa, my Smart car, with 115,000 kilometers, presented a significant electrical challenge due to prolonged inactivity of nearly six years. My repair process is methodical, addressing each issue step-by-step. Another project on the horizon is a redesigned cabin light assembly, as the original is beyond repair. Fortunately, the original lens is still in good condition and will be incorporated into the new, 3D printed assembly. Furthermore, a custom 3D printed fascia is in development to seamlessly integrate an aftermarket stereo into the dashboard.
Currently, the primary concern is the car’s charging system and overheating issues, likely pointing to a worn serpentine belt. Despite the extensive to-do list, owning this Smart car has been a long-held aspiration, making the restoration process genuinely enjoyable. I intend to document and share my 3D printed parts journey, including original design files (created in SolidWorks, for those interested).
I’m eager to hear from fellow enthusiasts about specific plastic parts you’d like to see developed. The modular bolt-on tray section beneath the stereo is already on my radar for potential modernization upgrades. With my background as an electronics engineering technologist and a keen interest in mechanical engineering, I’m also contemplating more advanced modifications. Imagine auto-dimming high beam headlights, rain-sensing automatic wipers, or even digital climate controls! While the extent of these modifications is still under consideration, I’m open to suggestions. Share your ideas, and I might just bring them to life and share the designs with the community.
