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An unobtainable dashboard console, rebuilt exactly as it was — sturdy enough to live inside a cabin, with the look of an original injection-moulded part.
The client entrusted us with making a set of parts to restore the interior console of a classic Mazda. With the 3D model supplied, our role was to produce a part faithful to the original, with a finish as close as possible to injection-moulded plastic, taking into account the aesthetic and technical constraints tied to fitting it into the vehicle.
These parts were meant to replace the broken pieces of the console inside the cabin, with enough durability to withstand the heat of a car interior. 3D printing was chosen as the only realistic alternative to moulding, which would have been far too costly for a one-off part.
Our mission was to achieve a visual finish close to injection-moulded plastic while guaranteeing the strength of the fixing areas. We optimised the print settings (minimum layer height, orientation, filament type) and tested several finishes to fully meet the client's expectations, all while keeping excellent mechanical behaviour.
The supplied file needed no changes, but we worked at length on the orientation of the part during slicing in order to preserve the strength of the fixing clips. We used a glossy black PETG filament, with a variable layer height optimised for the visible areas. Ironing was applied to some exposed surfaces to improve the finish, without resorting to any manual post-processing.
After a first print that was unsatisfactory in terms of finish, we offered the client a test printed on a textured plate with a carbon effect. This choice transformed the look of the console's lower surface, giving it depth and a premium sheen that the client greatly appreciated. This solution was adopted and made it possible to produce a part combining aesthetics and strength, with no further touch-ups.
The client was thrilled with the final result of the new console, feeling that the part exceeded their expectations. Contributing to the restoration of a classic vehicle was a moment of pride for our team, who are equally passionate about projects that mean something to their owners. This was a one-off project, but it led us to reconsider textured plates as genuine tools for aesthetic finishing. We have since expanded our collection and are preparing samples to offer bespoke finishes to future clients.
When a part no longer exists and the original tooling is out of reach, 3D printing makes it possible to rebuild it as a single unit, faithful and functional. A classic console thus finds its way back into the cabin, with no compromise on the finish.
The part exceeded my expectations: looks and strength together, without a single touch-up.
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