The Challenge

A client was restoring a classic custom car and needed a specific insert for a cast aluminum "badge" holder. Because the holder is a vintage cast piece, its internal dimensions are irregular and organic, making traditional manual measurements insufficient for a perfect, flush fit. The requirement was for a transparent plastic piece that would perfectly seat inside the chrome housing to serve as a substrate for a custom vinyl wrap.

The Solution

To capture the intricate internal geometry of the cast aluminum holder, the part was first 3D scanned. This scan data was imported into Fusion 360, where a custom insert was modeled to match the unique contours of the casting precisely.

The final part was manufactured using clear SLA resin to provide the required transparency and a smooth surface finish suitable for vinyl application. This method ensured that the insert snapped into the badge holder with a high-fidelity fit that manual fabrication could not have achieved.

Key Features

Process: 3D scanning and digital modeling for high-accuracy fitment.
Material: Clear SLA resin for transparency and surface smoothness.
Application: Automotive restoration and custom badge branding.
Engineering: Converting physical cast geometry into a precise digital CAD model.
Compatibility: Designed to serve as a perfectly sized substrate for vinyl wrapping.

The Result

The client received a custom-engineered component that seamlessly integrated with their vintage hardware. This project highlights the power of 3D scanning in the automotive sector, allowing for the creation of perfectly fitted parts for one-of-a-kind vintage vehicles without the need for invasive or permanent modifications to the original chrome.

Custom Transparent Insert for Classic Car Badge