Reverse engineering an unavailable car part: 3D scanning and printing of the Renault Alaskan headlight cover

When the original spare part does not exist

The unavailability of spare parts is an increasingly common problem - especially for older or less common vehicle models. A typical example was a job where a client needed to replace a missing headlight cover on a Renault Alaskan. The original part was no longer available and without a complete cover, the car could not be sold without complications.

The solution was reverse engineering using 3D scanning and additive manufacturing, which allows even complex plastic components to be quickly reproduced without the need for manufacturing documentation.

Solution process: from scan to final part

The client provided a preserved right headlight cover, which we used as a reference sample. The procedure involved several steps:

• 3D scanning of the part - digitizing the geometry to create an accurate CAD model
• Data editing and preparation - optimizing the model for production
• 3D printing in PA12 material - a strong and durable polyamide suitable for functional parts
• Final surface treatment by painting - achieving aesthetic and functional quality

The result was a complete set of left and right covers, visually and functionally matching the original parts.

Economic comparison of solutions

If available, a new original cover would cost approximately 12,500 CZK each.

Thanks to the use of 3D technology it was possible to 3D print the PA12 cover for 8 200 CZK / piece. The cost of painting, 3D scanning and data preparation had to be added to the price. Speed of delivery was key here, as the new part was unavailable worldwide with a waiting time of more than 6 months. However, the client was pressed for time as they needed to sell the car within 4 weeks where they were due to receive the new car and were therefore willing to pay the higher costs to get everything done within the timeframe.

Result: a working part and a happy client

The order fulfilled its main goal - the client was able to sell the car without complications.

"Reverse engineering in combination with 3D scanning and additive manufacturing now makes it possible to quickly and economically replace even parts that have been unavailable for a long time. In this case, we were able to create a functional and visually matching component from a reference part without the need for manufacturing documentation or molds."

Lukáš Jílek, 3Dees Industries

Reverse engineering as a practical solution for unavailable parts

This project demonstrates well how 3D scanning, additive manufacturing and professional post-processing technologies can help where traditional supply chains fail.

3D printing today enables:

• reproduction of unavailable spare parts,
• rapid production of functional plastic components,
• economical production of small batches,
• flexible design modifications without costly molds.

For the automotive, industrial and service segments, reverse engineering is thus an increasingly common and efficient alternative to conventional manufacturing.