For a new motorhome project, the design team wanted to visualise the model in physical space to test different exterior mouldings. The brief was to create a 1:12 scale model which would have interchangeable mouldings so that different concepts could be previewed.
I started by preparing the CAD for the existing parts for 3D printing by taking exterior surfaces and filling them out as they were scaled down considerably.
The Peugeot cab straight off the 3D printer, without having had support material removed.
The cab was only exterior surfaces, and so a lot of gap-filling had to occur to make it solid. This was the first part to be printed, and everything was built around this. I then printed a chassis to support the "living area". It was printed in 2 parts and fixed to the cab with screws.
The cab and chassis assembled for the first time to test fitment.
The living area was too big and would have been a waste of material and time to print. I fabricated the rough shape using some offcuts from motorhome side panels and some 2-part filler, and printed some corner pieces to keep the curves consistent.
The living area in progress, showing the construction using side panel offcuts.
While I was making the living area, I asked the paint shop to paint the cab to look more authentic.
The painted cab assembled with the chassis.
To secure the living area to the chassis I used the 3D printed corners to fix at the back and tension straps at the front, meaning if needed the whole back could be replaced (which it was eventually).
I printed a rack with mounting points for the interchangeable mouldings, This sits between the cab and the "living area", which was also painted to match the walls and roof of production vans.
Fully painted cab + living area, ready to accept modular components.
Finally, some finishing touches were printed, such as windows and doors. Several iterations of the external mouldings were printed and could be mixed and matched at will.
The finished piece, with interchangeable mouldings and additional features.
