Hextech Car Accessories: an Introduction to DIY Car Customization

Summary:

The following will be a how-to tutorial on how to create car parts for Acura RSX models. Based on knowledge of cars, 3d printing, and resin casting you can follow the two provided tutorial paths The tools and resources required will be shown below as well as with my own insight from the trial and error experience of designing the molds. The result will lead to either 3d printed or resin casting variants of the car parts I have designed for my senior thesis. 

Intro: Have you ever wanted to customize your car to another level? Are basic decals and steering wheel covers getting boring? Well that's no longer a problem with Hextech Car Accessories. From the comfort of your own home these parts can be manufactured and customized to your own liking (Do produce these in a safe workshop or work area space though as many of these materials can be toxic, with that said it is recommended to wear a mask for these processes). Made specifically for the Acura RSX (2002-2006). 

Based on your knowledge of cars, 3d printing, and Resin Casting, you can choose between one of two manufacturing Methods (resin casting is recommended for higher surface quality however). Any 3d printing related steps will be marked with an asterisk and can be skipped if you are outsourcing your parts.  

If you would consider yourself new to cars, 3d printing, and resin casting then the first process is recommended to you. This method allows you to outsource your 3d prints, skip resin casting, and just deal with the assembly and finishing of your part. This means that using the supplied 3d printer files, you can have your 3d prints made for you and shipped to you using a third party service. With 3d printing now becoming more accessible, 3d printing services can be accessed online or even through local stores or libraries. However, be aware that the level of surface quality and customization may vary depending on a number of factors. 

If you would consider yourself experienced with cars, 3d printing, and resin casting then the second option is recommended for you. Resin casting will allow for a higher level of surface quality and customization. 

3D Printing Estimated Cost:

Resin Casting Estimated Cost:

Supplies:

(Beginner Route) If 3D Printing Parts:

<For 3D Printing (Beginner’s Route)>

For 3D Printing:

•Supplied STL Files*

•Computer or Laptop*

•Slicing Software*

•3D Printer*

• ABS or PLA+ 3D Printer Filament*

•Paint Scraper*

•Super Glue*

•Duct Tape*

For Assembly and Finishing

•Sand Paper

•Spray Paint

•Car Polish

<<For Resin Casting (Experienced Route)>>

(Experienced Route) If Resin Casting Parts:

For 3D Printing:

•Supplied STL Files*

•Computer or Laptop*

•Slicing Software*

•3D Printer*

•ABS or PLA+ 3D Printer Filament*

•Paint Scraper*

•Glue Stick*

•Duct Tape*

For Resin Casting:

•Envirotex Lite High Gloss Finish Epoxy Resin

•Acrylic Paint (color and brand of choice)

•Plastic Knife or Popsicle Sticks

•Plastic Stacker Cups

•Beeswax Wood Polisher and Conditioner

•Mold Release

•Microfiber Rags

•Bag of Rice

•Metric Scale

•Zip Ties

•Box Cutter Knife

•Exacto Knife

•Flathead Screwdriver

For Assembly and Finishing

  •Sand Paper

•Spray Paint

•Car Polish

•Hand Sander

•Car Polish attachment

Extra

*3D Printing Video*

 3D Print Parts

     The supplied stl files can be printed to create the fog light cover and trim. Be aware that this method was not tested as much and final results can vary. The assembly consists of 3 parts that can be superglued together. It is recommended that the parts be sanded and sprayed with light coats of spackle from a spray gun. These extra steps aren't required but recommended for best results. 

•Download the supplied STL Files for 3d prints

•Import stl files into recommended slicer software

•Orient parts carefully and add supports as needed

•Slice and Prepare parts for 3D Printing

•Prepare 3d Printer for 3D Prints

•Apply Duct tape to printer bed

•Apply Glue Stick on top of duct tape

•3d print and make sure first layers are desirable

•once print is finished remove with paint scraper

Finishing

  The supplied stl files can be printed to create the fog light cover and trim. Be aware that this method was not tested as much and final results can vary. The assembly consists of 3 parts that can be superglued together. It is recommended that the parts be sanded and sprayed with light coats of spackle from a spray gun. These extra steps aren't required but recommended for best results. 

•sand down parts accordingly and carefully

•Spray parts with light coats of wood filler

•Wait for application to dry and harden

•sand accordingly and carefully

•Spray paint 2-3 coats of paint

•Assemble Parts with Superglue

•Gather Screws 

•Place Part into Fog Light Cover Hole and Insert screws through both the installation holes and the part

•Tighten Assembly by tightening the hex nut

•Enjoy your new car Part!

3D Printing Steps Recap

1. 3D Print Parts
2. Finish and Assemble the Fog Light Cover

<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<<>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>>

*3D Printing Video*

1.  3D Print Mold Parts

     The supplied stl files can be printed to create the molds for Resin Casting these car parts as well. The assembly consists of 3 parts and 5 3d printed molds that need to be made in order for resin casting to begin. It is recommended that the 3d prints are finished with the utmost best quality so that the surfaces of your final result are desirable.

•Download the supplied STL Files for 3d prints

•Import stl files into recommended slicer software

•Orient parts carefully and add supports as needed

•Slice and Prepare parts for 3D Printing

•Prepare 3d Printer for 3D Prints

•Apply Duct tape to printer bed

•Apply Glue Stick on top of duct tape

•3d print and make sure first layers are desirable

•once print is finished remove with paint scraper

3D Printing Insight

The following model was 3d printed on a makerbot 3d printer. The total print time was about 25 hours with raft supports. The print was mostly successful however there were many flaws in the outcome. Warping was a big problem with such a long print as I was using ABS and the print had to be on the print bed for over a day. Another flaw was the overall finish of the print. IT  was extremely difficult to get the raft supports off of the face of the foglight cover after it was done. Last but not least, the overall print time was way too long to wait for one part for. This is part of the reason why I have decided to move on with resin casting as a means for production.

Molds were 3d printed on Ankermake M5 and Ultimaker 5 3D Printers

Layer Heights were as follows: 

15mm layer height for prints on the Ultimaker 5

20mm layer height for prints on Ankermake M5  

PETG / ABS is recommended for 3d Printing

PETG is more prone to Warping and sticking onto 3d print beds

Duct Tape with Glue stick application is recommended

The provided 3d printer files are created with the intent to be 3d printed on most desktop 3d printers. If you are confident in your 3d printing abilities and 3d printer, then most of these parts can be 3d printed at the comfort of your own home. Otherwise, I'd recommend 3d printing services for better guaranteed surface quality. My recommendation is to 3d model the new original design so that the part can be prototyped and 3d printed. Hand crafting can be done as well but will take addition work

When epoxy resin is mixed with both mixtures into a form it is able to be casted. The resulting mixture cures for 24 hours and is then able to be used. Food coloring is able to be added at this point.

• First start off by weighing the cup that you will be using to store your rice in
• After you will start to pour your rice into your mold. This is to figure out how much resin you will need for each part
• Fill the mold part thoroughly and spread throughout
• Pack Rice in so that the weight measurement is as accurate as possible
• Pour Rice back into the original cup and weigh again 
• Subtract the cups weight from this new measurement 
• This will give you an estimate of how much weight in resin that will be required for each mold, repeat this process for each mold
• Prepare the molds with beeswax by applying dabs into the mold and onto fabric cloths, spread throughout until entire surface is covered
• Wipe any excessive globs as these can create imperfections in the resin pour
• Spray Mold release and wipe any excessive wet spots as well 
• Pour Measure amount of Resin into one cup
• Pour Measured amount of Hardener into second cup
• Add Hardener into first cup with resin
• Add 5-10 Drops of Acrylic Paint
• Mix the epoxy for 1 minute, stirring against the cup to scrape excess off of the cups walls
• After the first mix is done pour the mixture into a new clean cup
• Mix for another minute
• Now resin can be Pressurized for better quality and less air bubbles
• Pour Resin into Mold, Pour at such an angle that the cups lip slowly releases the epoxy while also popping bubbles 
• Pour slowly so that the stream is skinny and overlaps itself, this will allow bubbles to pop while pouring into the mold as well
• Let resin flow throughout part, fill a bit excessively until molds are full 
• Set Mold Part into Pressure Pot
• Pressurized the Mold within the pot until it is -10psi, leave for 1 minute 30 seconds and then decompress, repeat this 5 times
• Place the pot on an even surface
• Let the part cure in the pot for 24 hours, as the pot is a clean space without dust
• After the parts are fully cured they can be removed from their molds
• It is recommended that for the flat parts to be etched out with exacto blades and box cutter knives before releasing the part. The dips in the molds are the edges of the resin parts that would be pried first
• Once the part starts to release a flathead can be used to release the part slowly but surely, make sure not to damage the resin parts and take your time
• Rest the parts on flat surfaces so that dont warp or bend

Installation (Experienced Route)

Sanding and Polishing 

The supplied stl files can be printed to create the molds for Resin Casting these car parts as well. The assembly consists of 3 parts and 5 3d printed molds that need to be made in order for resin casting to begin. It is recommended that the 3d prints are finished with the utmost best quality so that the surfaces of your final result are desirable.

•Once the parts are fully removed they can start to be polished and finished

•Clean the parts with green spray and or a wet cloth

•Sand the parts individually with car sand paper kits, starting from the lower grits to the higher grits, starting with 200,

•spray the part with green spray and get rid of dust with cloth after every sand grit rating

•Get hand sander and apply car polisher attachment to end

•Apply car polish to the end

•Apply dabs of car polish to each of the resin parts

•Turn hand sander to appropriate rotation speeds and apply polish in circular motion

•Polish outside surfaces the most as they will be the most exposed and seen

•Wipe excessive polish with cloth

•Super Glue Resin Parts together and let cure for 24 Hours

Sanding and Polishing 

The supplied stl files can be printed to create the molds for Resin Casting these car parts as well. The assembly consists of 3 parts and 5 3d printed molds that need to be made in order for resin casting to begin. It is recommended that the 3d prints are finished with the utmost best quality so that the surfaces of your final result are desirable.

•Gather Screws 

•Place Part into Fog Light Cover Hole and Insert screws through both the installation holes and the part

•Tighten Assembly by tightening the hex nut

•Enjoy your new car Part!

Sanding and Polishing 

The supplied stl files can be printed to create the molds for Resin Casting these car parts as well. The assembly consists of 3 parts and 5 3d printed molds that need to be made in order for resin casting to begin. It is recommended that the 3d prints are finished with the utmost best quality so that the surfaces of your final result are desirable.

•Gather Screws 

•Place Part into Fog Light Cover Hole and Insert screws through both the installation holes and the part

•Tighten Assembly by tightening the hex nut

•Enjoy your new car Part!