Idea to Prototype to Final Product

The 2004 STi came with covers over where the fog lights are on other models and included the famous motorsport logo decal on them. Long story short, these were an iconic visual element that fans of this car love. I set out to design these for the new gen.

Initial rough concepts. There were so many more than this.

Final concept in Maya, time to do it for real in CAD.

The bezel that my fog cover design would attach to was sent to a local 3D scanning shop. I rebuild it in Fusion using the point cloud data.

A comical amount of print hours to get to this point where I was happy with it.

Once things were getting really solidified, I opted to get some higher quality prints with SLA and SLS to test tolerance and paint mockups.

Final Part design in Fusion

First tooling! There was an error on the manufacturer's end where an internal miscommunication happened, and the team making the tooling ended up making a positive tool, instead of a negative. The final looked like this but inverted. Paper trail ftw!

First shipment of test run

Unboxing and inspecting tolerances

Final run of parts after finishing in OEM paint and coating