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Here is another project I'm working on over on the Facebook group. This is what started me on the tangent of reproducing the speaker mount rings in my other post.
I purchased a JDM double DIN panel a couple years ago but was disappointed at how poorly it fit. It had been trimmed by a previous owner, so I'm not sure how much of the problem was the trimming job but I have never found another panel for sale since.
I had tried to 3D scan the panel using a ToF sensor and Kinect setup a friend had but that proved to be an impossible task - The scan was filled with enough garbage data points that the output wasn't accurate, so the panel sat on the shelf until this week.
I finally purchased a better 3D scanner, intending to use it for my other CAD and product design projects, and then I remembered the panel.
My intent is to use the 3D scans to import the more complex geometry into CAD which will allow me to "reverse engineer" the part - Really, just copy the contours and mounting points without having to measure nearly as much. I have a few choices for "production" panels if I get that far...
A. 3D printed panels, either produced in-house and sold, or with the files open source and available. With the layer lines inherent in 3D prints and the post processing required, as well as it being a very large piece for most 3D printers and having to be printed in ABS, ASA or some other high(er) temp material, I don't see this as being the best option.
B. Vacuum formed pieces (Either PVC foam, ABS sheet or PP sheet). This would require a buck be CNC machined but parts could be produced relatively quickly. The mounting points would still need to be 3D printed or cast, and precisely glued into place. I think this is the best option that would produce the cheapest parts with a textured "professional" appearance.
C. An injection molding process. I've done one mold before, and something of this size would likely cost around $15k for the molds, but parts would be around $2-4 apiece after that. I don't think there would be enough of a demand to justify such a cost, though it would provide parts of the same quality as the originals - Just mirrored to fit our LHD Insights. If I sold the panels at say $50 apiece, it would take over 300 panels just to break even on the molds. (No idea what these should/will cost, just throwing out a number that seems reasonable to me)
So my progress so far - I have 3D scanned the dash of my Insight, as well as the single DIN and double DIN panels. I mirrored the double DIN scan in CAD and confirmed it fits the contours of my dash nearly perfectly. My scans of the panels are not great since I was still learning to use the scanner, so I may redo those before I start designing.
I'd like to get comments on interest in this project (If any). Suggestions also welcome! Since I have so much freedom over the design I could redesign the panel to fill the entire area where our original cupholders are, and add a tray, area for another piece of audio equipment, USB outputs, OBDC&C mount... The possibilities are endless. I am also considering a fully custom designed center console once I install my CRZ seats, pending measurements - I'm not sure how much room will be left in the middle. If moving the ebrake to the side could be accomplished, a cupholder and armrest could potentially be designed into the center console.
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I purchased a JDM double DIN panel a couple years ago but was disappointed at how poorly it fit. It had been trimmed by a previous owner, so I'm not sure how much of the problem was the trimming job but I have never found another panel for sale since.
I had tried to 3D scan the panel using a ToF sensor and Kinect setup a friend had but that proved to be an impossible task - The scan was filled with enough garbage data points that the output wasn't accurate, so the panel sat on the shelf until this week.
I finally purchased a better 3D scanner, intending to use it for my other CAD and product design projects, and then I remembered the panel.
My intent is to use the 3D scans to import the more complex geometry into CAD which will allow me to "reverse engineer" the part - Really, just copy the contours and mounting points without having to measure nearly as much. I have a few choices for "production" panels if I get that far...
A. 3D printed panels, either produced in-house and sold, or with the files open source and available. With the layer lines inherent in 3D prints and the post processing required, as well as it being a very large piece for most 3D printers and having to be printed in ABS, ASA or some other high(er) temp material, I don't see this as being the best option.
B. Vacuum formed pieces (Either PVC foam, ABS sheet or PP sheet). This would require a buck be CNC machined but parts could be produced relatively quickly. The mounting points would still need to be 3D printed or cast, and precisely glued into place. I think this is the best option that would produce the cheapest parts with a textured "professional" appearance.
C. An injection molding process. I've done one mold before, and something of this size would likely cost around $15k for the molds, but parts would be around $2-4 apiece after that. I don't think there would be enough of a demand to justify such a cost, though it would provide parts of the same quality as the originals - Just mirrored to fit our LHD Insights. If I sold the panels at say $50 apiece, it would take over 300 panels just to break even on the molds. (No idea what these should/will cost, just throwing out a number that seems reasonable to me)
So my progress so far - I have 3D scanned the dash of my Insight, as well as the single DIN and double DIN panels. I mirrored the double DIN scan in CAD and confirmed it fits the contours of my dash nearly perfectly. My scans of the panels are not great since I was still learning to use the scanner, so I may redo those before I start designing.
I'd like to get comments on interest in this project (If any). Suggestions also welcome! Since I have so much freedom over the design I could redesign the panel to fill the entire area where our original cupholders are, and add a tray, area for another piece of audio equipment, USB outputs, OBDC&C mount... The possibilities are endless. I am also considering a fully custom designed center console once I install my CRZ seats, pending measurements - I'm not sure how much room will be left in the middle. If moving the ebrake to the side could be accomplished, a cupholder and armrest could potentially be designed into the center console.
