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Large-format parts for a grader driving simulator: large-format FDM printing (V-Core 4.0, 500 × 500 × 500 mm) in PETG for strength — a small batch without the cost of a mould. The parts fitted perfectly, and the simulator is now up and running for training drivers.
As part of building a grader driving simulator, the client entrusted us with printing a batch of large parts. The supplied 3D files had to be reproduced accurately to guarantee a perfect fit within the driver's station, with a visual finish faithful to the original.
These parts are intended for training drivers on an indoor driving simulator. Bespoke 3D printing proved ideal for producing a small batch without incurring the cost of a mould, while ensuring enough durability for regular use. The overall visual realism was also a key requirement.
We focused on producing large, complex parts while optimising the print settings to guarantee both strength and visual quality. One of the major challenges: using our large-format machine, which requires rigorous maintenance and close monitoring throughout the print.
Although the files for the driving simulator were supplied by the client, we worked on the orientation of the parts at the slicing stage to optimise strength and avoid defects during printing. No design change was needed, but we factored in the longer lead times linked to the size of these parts.
We used FDM 3D printing, the only technology suited to the large dimensions of this project. Thanks to our V-Core 4.0 printer (500 × 500 × 500 mm), we were able to print in a single piece, with PETG chosen strategically for the strength required by the driving simulator. The machine was pushed to the limit of its capabilities, calling for long prints and constant attention.
No post-print finishing was required. The focus was on careful packaging to protect these large parts during transport. Once installed on the simulator, the parts fitted perfectly, fully meeting the client's expectations. The driver's station is now operational, actively contributing to the training of future drivers.
Bulky parts printed in large-format FDM, fitted with no rework. The simulator is operational, without the lead times or investment of dedicated tooling.
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