YouTuber tests desktop 3D printing limits by making full-scale Porsche body panels.
Automotive YouTuber Mike Lake has launched a long-term project: using affordable desktop 3D printers to create full-scale exterior body panels for a Porsche 992 GT3 RS sports car. This endeavor aims to test the limits of producing functional real-car parts solely with commercially available 3D printers, without relying on industrial-grade equipment.
This project explores whether an individual can manufacture full-scale automotive exterior panels using desktop 3D printers. The focus is solely on exterior cosmetic parts; the vehicle's chassis, frame, and any safety-critical components remain entirely unmodified.
The exterior panels are divided into segments that fit the build volume of consumer 3D printers. They are printed sequentially and later assembled by hand. The material used is PETG, chosen for its relative resistance to UV light and heat, as well as its ease of use for large prints. A single front fender, for instance, comprises over 20 individual parts, with material costs kept to just several thousand yen.
In the initial stages, challenges typical of large-scale printing—such as warping and layer separation due to temperature fluctuations—were encountered. However, by adjusting printing temperatures and enclosing the printer, stable printing was achieved. The part design was also revised to a hollow, lightweight structure, significantly reducing both material usage and overall weight.
After assembly, the panels' seams are welded and bonded for strength, with fiberglass reinforcement added to the backside. The surfaces are then shaped through sanding and finishing. Despite being printed in segments, the achieved accuracy allows for potential mounting on an actual vehicle. The weight of the reinforced parts is reported to be close to that of original factory components.
This experiment demonstrates that consumer-grade 3D printers are becoming a viable option for prototyping and custom fabrication applications. On the other hand, it also highlights clear limitations for mass production, such as long print times and the labor-intensive post-processing required.
