Streamlining Repairs with 3D Scanning and Printing: A Mitsubishi Colt Fog Light Bezel Replacement

When replacement parts become unavailable, finding creative solutions can make all the difference. Local panel and paint repair shop Wilson Collision Repairs Whakatane approached us with a unique challenge: they needed a replacement fog light bezel for a Mitsubishi Colt that had been in an accident. The part was no longer manufactured, and sourcing a used replacement was going to be very time consuming. By leveraging our expertise in 3D scanning and 3D printing, we delivered a fast and cost-effective solution, keeping the repair on schedule.

3D Scan to CAD model preparation & printing

The client required a replacement fog light bezel to complete the fit between the bumper and the fog light itself. While the damaged side bezel was beyond repair, they provided the opposite side in good condition as a reference. This project was part of an insurance job, where minimizing downtime was critical to meeting repair deadlines. Our challenge was to create a precise, durable, and cost-efficient one-off replacement part.

3D Scanning the Part

• Using 3D scanning, we captured the geometry of the existing fog light bezel. Multiple scans were merged to create a complete, accurate digital model of the part. The data was cleaned up to remove noise, fill small holes, and refine the mesh, a solid model was created from the mesh by using the surface tools inside Creaform VX Model Software

CAD Modeling

• We imported the data into Autodesk Inventor, ensuring it matched the original part’s dimensions and contours. Support structures were also designed to ensure a stable orientation for the 3D printing process.

Filament 3D Printing

• Given the one-off nature of the part, filament-based 3D printing was chosen as the most cost-effective solution. While resin printing offers finer detail, it was unnecessary for this application and would have increased costs. The filament-printed part was robust and provided the precision needed for the repair.

Finishing

• The client handled post-processing, including trimming support material, sanding, and preparing the part for painting. After priming and painting to match the vehicle, the fog light bezel seamlessly clipped back into the bumper.

Results and Impact

By turning to 3D scanning and printing, the client avoided the weeks or months it could have taken to source the part through traditional methods. The repair shop was able to complete the job efficiently, meeting the insurance deadline and ensuring their customer’s vehicle was restored to a like-new condition.

This project highlights the value of digital manufacturing in reducing lead times, saving costs, and overcoming supply chain challenges.

Have a hard-to-source part or unique project in mind? Reach out to us to explore how our 3D scanning, CAD design, and 3D printing services can save you time and keep your projects moving forward.

“Learn how we used 3D scanning and filament 3D printing to create a custom fog light bezel for a Mitsubishi Colt. Discover how digital manufacturing helps automotive repair shops save time and costs while meeting tight deadlines.”