Honda CRX DX HF SI 1988-1991 Heater HVAC reproduction
As part of this project, the housing of a climate control panel from a 1989 second-generation Honda CR-X was reproduced. The original component had suffered material fatigue, with several areas cracked or broken. Once the panel was disassembled, the damaged and deformed sections became visible, as shown in the images below.
The first step involved scanning the component. The data points captured during the scanning process later served as the basis for constructing a parametric CAD model. Scanning was carried out using an Einscan SP V2 desktop scanner, which employs structured light technology and features an automated rotary table.
Since the component is black, it does not reflect sufficient light for the scanner to operate effectively. For this reason, scanning could only be carried out with the use of a scanning aid. Numerous products developed for this purpose are available on the market. From this wide selection, the AESUB-blue spray was chosen. Its primary advantage is the ability to apply a thin, homogeneous white coating to the object’s surface. The material evaporates within a few hours of application, eliminating the need for post-cleaning. Prior to spraying, all contaminants were removed from the surface to ensure the scanned data would represent the original object as accurately as possible.
The scanning process yielded a mesh model of the component. In its raw form, this model was unsuitable for 3D printing, as it contained missing details as well as the fractures and deformations observed in the original part. For this reason, a completely new model had to be built, using the scanned data as a reference. The result of this process is illustrated below, showing the reconstructed CAD model alongside a comparison with the original mesh.
The finalized model was then transferred into the printer’s slicing software and oriented as shown in the images. Printing, as in most cases, was carried out on a Formlabs Fuse 1+ 30W SLS printer. This technology is ideally suited for such an application, as the component features a relatively complex geometry with numerous fine details.
Following the print, the raw part underwent post-processing to achieve its final appearance. The surface was primed, painted, and lacquered, resulting in both a finish identical to the original and a UV- and scratch-resistant surface.
This component demonstrates well the types of applications for which SLS technology is particularly suitable. All fine details of the finished part are clearly defined, and the mechanical strength is appropriate for its intended use. Furthermore, the precision of the technology ensures that once assembled, the buttons fit correctly into their positions and operate smoothly without interference.
You can find the final procuct here.
