HOOK COVER FOR A CAR

In 3WAY, in addition to selling products in the field of 3D technology, of course, we also offer integrated services. We strive for the most optimal solution to the problem. This time, the customer had a problem that particularly attracted us. Using Shining3D EinScan HX 3D scanner, CAD modeling in ThinkDesign, and 3D printing on Intamsys Funmat HT, we created a unique hook cover for the car.

Hook cover for Tesla

IT ALL STARTS WITH A PROBLEM AND AN IDEA

Nowadays, the problem is no longer so difficult to solve, you only need to find a service that provides it. In 3WAY, we offer solutions using the latest and most advanced 3D technology. The customer came to us with a problem that was very interesting for us as well. The hook cover on the car fell off while driving or was stolen, and the customer needed a new one.

Tesla

We got an idea of ​​how to fill a hole in the chassis, using the full spectrum of 3D technology. Of course, something like this requires enough knowledge and experience. Initially, part of the chassis had to be scanned with a 3D scanner, and the data obtained was processed. This was followed by 3D modeling and finally 3D printing of the hook cover. Are you interested in the details of the whole process?

EINSCAN HX

3D SCANNING WITH SHINING3D EINSCAN HX

The hook gap that needed to be closed was located at the bottom of the car. Access was a bit more difficult as part of the chassis had to be scanned. We decided to use the EinScan HX 3D scanner, which is convenient and very accurate for capturing surfaces. It was not necessary to apply spray or markers on the surface and despite the difficult accessibility, we managed a very good scan.

Scanning the chassis of Tesla with EinScan HX

Scanning the part of the chassis with EinScan HX.

Scanning the chassis of Tesla with EinScan HX

Accessibility was a bit difficult, but we managed a very good scan.

3D scanning was followed by processing data of the scanned part in the software of the EinScan HX scanner. With a few corrections, we got a good enough model that represented a solid basis for further work.

Obdelava skena

Data processing.

Obdelava skena

The scan represented a solid basis for further work.

THINKDESIGN

MODELING THE HOOK COVER IN THINKDESIGN

We used ThinkDesign for the hook cover modeling. ThinkDesign includes many useful features and is an excellent platform for drawing a model of any shape. Quite a few factors had to be taken into accounts, such as resistance to vibrations when driving and the outside temperature. Electric cars do not overheat to the same extent as others, but in the summer months, the reflection of the sun’s rays can quickly lead to too high values.

Modeling the hook cover in ThinkDesign

CAD model of the hook cover made in ThinkDesign.

Modeling the hook cover in ThinkDesign

Side view of the hook cover.

As you can see in the pictures, the hook cover is not made of a single piece but consists of several smaller ones. The central part consists of two larger surfaces that close the opening and are connected by a folding element for easier installation. The plates have an additional rib element, which allows sufficient rigidity and prevents bending. They are made of ABS plastic.

The side pins are made separately as if any breaks it is not necessary to replace the entire plates but simply replace just them. They are made of ASA plastic.

Two more screws had to be made for fastening. They were screwed into the chassis, which stabilized the cover in place.

Modeling the hook cover in ThinkDesign

The inner part of the cover, where all the elements can be seen – pins, ribs, connecting elements, etc.

Modeling the hook cover in ThinkDesign

External or visible part of the cover.

The last element is the pins of the intermediate plates, which are made of flexible plastic to make the installation as tight as possible. The intermediate plates are removed using the hook. The central one is intended for the hook itself, and the other is for the electrical wiring. In addition, we made a special tool for easier removal.

INTAMSYS FUNMAT HT

3D PRINTING OF THE HOOK COVER ON INTAMSYS FUNMAT HT

To print the pieces, we decided to use the Intamsys Funmat HT 3D printer, as it offers industrial-grade quality printed pieces. The advantage is the thoroughly insulated and heated chamber. With slow cooling, it allows the final piece not to curl. We were satisfied with the final product.

Hook cover printed on Intamsys Funmat HT

The final product printed on Intamsys Funmat HT.

Vijak za pritrditev.

The screw for cover fastening.

The screw for intermediate plates for the hook itself and electrical wiring removal

The special tool for intermediate plates for the hook itself and electrical wiring removal.

The visible part of the hook cover.

The visible part of the hook cover.

INSTALLATION OF THE HOOK COVER ON THE TESLA CAR

Mounting the cover was quick and easy. The gap has closed completely, leaving all the dirt outside the car’s chassis. We also tested the removal of both intermediate plates with a screw to make sure the customer could use the cover functionally. Everything went according to plan and we believe that the customer will be satisfied with the solution and the useful value of the hook cover for a long time in the future.

A brand new hook cover on Tesla

Mounting was quick and easy.

Functional value of the hook cover.

The cover has a functional value.