Replacing Obsolete Automotive Parts with SLS 3D Printing
Replacing Obsolete Automotive Parts with SLS 3D Printing
Some cars refuse to die, but their flimsy plastic interior knobs sure do. When a beloved daily driver ages, finding functional replacement parts for broken dashboard controls usually turns into an exhausting wild goose chase through junkyards and sketchy online listings.
The Bottleneck: A Snap-Happy Honda Climate Control Knob
The original temperature control knob on a client's trusty 1996 Honda Accord finally gave up the ghost after nearly three decades of loyal service. Every cheap aftermarket replacement the owner tried snapped under pressure shortly after installation, leaving him stuck with an unadjustable HVAC system. Tired of choosing between driving with oven mitts in July or a winter parka in January, the owner reached out to NW Rapid Manufacturing to engineer a rugged, permanent custom car part.
The Solution: CAD Modeling and Tough Nylon 12 SLS 3D Printing
Our team in McMinnville, Oregon, took the project from digital concept to finished hardware in just five business days. Using SolidWorks CAD design, we recreated the original geometry while reinforcing key stress points to prevent future cracks. We selected Nylon 12—an exceptionally tough, lightweight engineering thermoplastic ideal for functional automotive 3D printing—and produced the component using Selective Laser Sintering (SLS 3D printing). After printing, we dyed the raw component a sleek, factory-matching black to blend seamlessly into the Accord's interior dash.
The Results: 5-Day Turnaround and Permanent Cabin Comfort
Just five days after initial contact, the custom 3D printed replacement knob was installed and smoothly dialing in climate control. The owner regained effortless cabin temperature adjustment without hunting down rare obsolete automotive parts or settling for weak factory plastic. Thrilled with the outcome, the driver reported:
I was super pleased with the customer service, pricing, and quick delivery of my part!
Have an obsolete car part that needs a tough, custom replacement? Contact our McMinnville engineering team today or upload your CAD file to request a quote!