Case study: 3D printing restoration for Porsche 911 Targa

Anthony Millington, Creative Director at Amron Architectural, is a classic car enthusiast with a 1979 Porsche 911 Targa that is his pride and joy.

When he had an issue with the handbrake, Anthony took the Targa to the garage to fix but when they removed the cover off the handbrake, it simply disintegrated. As most people do these days, he went online to try and buy a replacement cover only to find they do not exist. The garage glued the existing cover back together, but it just didn’t look good, and its lack of strength wasn’t practical, given how much the car is used.

Anthony took the car away so he could investigate potential solutions. A friend who looks after Anthony’s BMX bikes showed him a part he had developed for a bike. The part had been 3D printed. That, decided Anthony, was the answer!

An internet search for a professional 3D Printing bureau in the local area suggested Prototype Projects and so Anthony got in touch to talk through the issue. Speaking with Adam Sharkey, Prototype Projects’ 3D Printing Team Leader, they agreed that Anthony should bring the part in to look at.

Adam recommended having the part 3D scanned which Anthony agreed to. Prior to scanning the part, Prototype Projects carried out some remedial work on the part as it was cracked and misshapen. Once the part had been scanned, further modifications were made to remove redundant holes that had been added as a result of previous modifications. The OEM hole for the heater controller was also removed as it was not required.

Once the file was approved, Prototype Projects applied a texture using a programme called ZBrush so the aesthetics would work well within the Porsche. It was then printed using SLS 3D Printing in PA 12 Nylon. Post-production, the part was smoothed and dyed black to match the OEM as closely as possible.

Anthony said,

‘It was like witchcraft! And the newly printed part was so much better than the original.’

Anthony returned to the garage so they could fit the new part.

Anthony said,

‘The garage was really impressed with the quality, saying that it’s not a model, but a working piece. The part is strong, and it fitted straight into the car. Now my handbrake works, and it looks smart. I am so pleased with the result.’

He continued,

‘Prototype Projects helped guide me through this whole process. They were patient with me and are clearly experts in their field. It’s made me realise the possibilities that 3D Printing offers and how it could really help the product development process within Amron. It’s also made me realise that there could be a gap in the market for my part, especially as it isn’t available from Porsche!’