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Porsche Is 3D Printing Hard-To-Find Parts For The 959 And Other Classics (jalopnik.com)

Porsche Classic, Porsche's classic cars division, has turned to 3D printing obscure parts that people might need on occasion. From a report: They already have about 52,000 parts available, but for the truly arcane ones, it's cheaper to 3D print them than make the specialized tools to create them over again. In addition to that 959 lever, Porsche is also 3D printing eight other parts. They are made from steel and alloy and the plastics are made using an selective laser sintering printer, which Porsche describes as: "A process where the material is heated to just below melting point and the remaining energy is applied through a laser to fuse the plastic powder at a selected point." So there you have it! The next time something is busted on your 959 or 356, don't cry and abandon the car, stalled on the side of the road. Call up Porsche. They'll science something for you.

52 of 82 comments (clear)

  1. As a gear head - this is nirvana by sinij · · Score: 1

    As a gear head, I can't wait until metal printing is affordable. Unobtanium parts are bane of my existence.

    1. Re:As a gear head - this is nirvana by Anonymous Coward · · Score: 1

      And as soon as metal printing is affordable, intellectual property laws will become the bane of your existence.

    2. Re:As a gear head - this is nirvana by Anonymous Coward · · Score: 1

      You can already print them in plastic or wax and cast your own pretty easily.

    3. Re:As a gear head - this is nirvana by sinij · · Score: 1

      And as soon as metal printing is affordable, intellectual property laws will become the bane of your existence.

      They will be as successful as *AA at stopping music torrents. So not at all.

    4. Re:As a gear head - this is nirvana by glenebob · · Score: 1

      Yes, because casting aluminum, iron, and steel is "pretty easy"...

    5. Re:As a gear head - this is nirvana by MangoCats · · Score: 2

      Now, the question for me is: as an owner of one of these cars, what would it cost to license the spare parts database so I can have a printing company of my choice make and finish the parts to my specifications?

    6. Re:As a gear head - this is nirvana by PhunkySchtuff · · Score: 1

      Yes, and cast parts have the same strength as forged or machined parts.

    7. Re:As a gear head - this is nirvana by nonBORG · · Score: 1

      If you have ever actually used 3D metal printing for small or fine parts, you will know it is not print and use. You need to spend some time finishing and fine detail (think gear teeth etc) don't work too well. Possibly they can improve it but chances are it will get worse when it gets cheaper. When we tried it the parts were unusable but we were trying to make parts that did not just look like something but were useful in a small unit. For something big and smooth like a lever seems like it would be ok. The company sent us a few samples of what they could do but our 3D print did not seem harder than the samples hardly yet was a failure. I suspect some marketing in there. There are some other useful manufacturing techniques like MIM (Metal Injection Molding) which we used to good effect. It was for keys on a Metal Keypad on a ATM but in this case we used an overmold of plastic (actually just the insides were plastic) to allow us to shine a light through the keys and have them backlit. Not really sure if MIM can go finer and better than the Metal 3D print. Both were in stainless.

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    8. Re:As a gear head - this is nirvana by BancBoy · · Score: 1

      You wouldn't download a car...part. Oh wait!

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    9. Re:As a gear head - this is nirvana by glenebob · · Score: 1

      Yes, especially the ones cast by a random person in their back yard.

    10. Re:As a gear head - this is nirvana by subk · · Score: 2

      Considering that there are only a couple hundred 959's in existence, I'd say a licensing effort would be pointless. They are no doubt charging dubiously huge fees for these 3D printed parts, but if you own a 959 money is already no object.

      Also, Porsche charges astronomical licensing fees for anything associated with their brand. Just look at video games for example.. Many times you will see RUF cars instead of actual Porsches in games because they want too much for licensing.

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    11. Re:As a gear head - this is nirvana by tlhIngan · · Score: 2

      Also, Porsche charges astronomical licensing fees for anything associated with their brand. Just look at video games for example.. Many times you will see RUF cars instead of actual Porsches in games because they want too much for licensing.

      Actually, that's not the reason why. The reason was EA had an exclusive license to use Porsche in its games Need for Speed and Real Racing. Exclusive, as in no one else was allowed.

      This agreement ended in 2016, after a 16 year exclusivity deal, which means you are now free to license Porsche for real, and I believe Forza and several others have in 2017.

    12. Re:As a gear head - this is nirvana by Anonymous Coward · · Score: 1

      Not true for steel, as featured here on /. not long ago.

    13. Re:As a gear head - this is nirvana by subk · · Score: 1

      Ahh. Thanks for the clarification.

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    14. Re:As a gear head - this is nirvana by Bert64 · · Score: 1

      Replicating a vehicle part will still have a significant cost, both in terms of actually making an accurate blueprint of the part, the time involved in 3d printing it, the cost of the required equipment and the cost of the raw materials. In many cases the 3d printed part might cost more than an original mass produced part, especially if that part is still being produced or the manufacturer has significant leftover stocks of it.

      If the manufacturer has given up selling those parts, then they'd have a harder time arguing against third party reproduction and are far less likely to care at that point too.

      Also there are already third party car parts available, even for current models of car. A lot of cars share common parts, even across different manufacturers and models.

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    15. Re:As a gear head - this is nirvana by thesupraman · · Score: 1

      Yes, quite.
      What we need next is some kind of machine that you can use to cur metal into shapes, perhaps using some kind of spinning tool and an x/y/z movable bed..

      Oh way, its called a milling machine, and combined with a tig welder, you can replicate a LOT of things without the problems associated with the random-and-unpredictable finish and strength of 3d metal printing.

      Metal printing will make 'easy' parts easy (remember, you have to come up with an accurate 3d model), and hard parts will still be hard.

      The parts that are real hard just dont 3d print anyway - gears for example are HORRIFIC when 3d printed due to a number of problems to do with finish strength and texture. Hollow parts can the big areas where 3d printing helps, but those are pretty rare on most cars (unless you think you will be printing a new block or piston..)

    16. Re:As a gear head - this is nirvana by AaronW · · Score: 1

      SpaceX has been very successful 3-D printing metal. For example, their SuperDraco engines are entirely 3-D printed. From what I have read and heard, they are able to do things with 3-D printing that are impossible any other way, including changing the properties of the metal based on location. Heating something to the melting point isn't necessary for strength (i.e. see friction stir welding). 3-D printing does not mean the parts are weak.

      3-D printed parts can be made lighter and contain far more complexity than non-additive manufacturing methods due to being able to create shapes and cavities that would normally be very difficult if not impossible. Metals can also be mixed in ways that are not possible with forging or casting.

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    17. Re:As a gear head - this is nirvana by AaronW · · Score: 1

      That is no longer true. In fact, you can have better control over grain size with 3-D printing than you can with casting. Additionally, you can change the metal composition based on location. SpaceX, for example, makes extensive use of 3-D printing of its metal parts. Their SuperDraco rocket engine is entirely 3-D printed, for example. Here's an older Slashdot story where 3-D printed stainless steel more than doubles the strength.

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  2. Science is a verb now? by Anonymous Coward · · Score: 2, Insightful

    Have we already gone full-on idiocracyin just 12 years?

    1. Re:Science is a verb now? by DontBeAMoran · · Score: 1

      Science isn't about WHY. It's about WHY NOT. Why is so much of our science dangerous? Why not marry safe science if you love it so much. In fact, why not invent a special safety door that won't hit you on the butt on the way out, because you are fired. - Cave Johnson

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    2. Re:Science is a verb now? by hey! · · Score: 1

      If you like it, you could pretend you don't understand.

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  3. Re:Why did they destroy the old tooling? by jellomizer · · Score: 1

    Because they didn't need them anymore.
    German efficiency + implementing Japanese Lean methodology , if you don't need it anymore get rid of it as it will be wasting space.

    For these older models, they don't need the space for a full production line. As most people will go to the Junk Yard to get the missing part. Offering 3d Printing of the part is probably the most affordable way to do it. As custom tooling a part will be wicked expensive.

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  4. 356? by i.r.id10t · · Score: 1

    Aahh... no.

    Porsche - or at least Porsche North America - got out of the 356 parts business around 2000, and sold all remaining NOS stock to Stoddard

    Fortunately, I have all the weird and special bits and pieces for my 356c coupe- and there are some skilled artisans making 3rd party metal parts for what I'll have to replace eventually (door skins, etc)

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  5. Re:Gay! by tbuddy · · Score: 1

    Nothing from the Porsche press release indicated anything about chrome parts. Appears to just be iron, plastic, and steel components.

  6. Re:Why did they destroy the old tooling? by Aaden42 · · Score: 2

    They didn't take it out back & blow it up, but machining tools don't last forever.

    Some of them were probably used (with modifications) in subsequent model years, most of them just wore out & weren't replaced since they weren't making that exact part anymore. For the rest, molds and tooling takes up space or rust and the materials they're made out of can be recycled into new parts. There isn't a lot of money to be made in keeping tooling for a 30+ year old car that they only made about 300 of to begin with.

  7. cue Tom Sellek : by Thud457 · · Score: 1

    You wouldn't download a car.

    But you will.

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    1. Re:cue Tom Sellek : by Freischutz · · Score: 1

      You wouldn't download a car. But you will.

      Cue Chairman Mao: A steel furnace in every home!

      Make fun of it, but this is the future of manufacturing. When 3D printing reaches the point where you can churn out the parts for whatever it is you need parts for locally, or just the make whole product at your local 3D printing shop from plans downloaded from the internet, it will upend the world of manufacturing as we know it in a big way. Never mind if we ever get to a point where you can 3D print your own AK-47 that can fire 30k rounds without the receiver breaking or the barrel exploding in your face like the original can or ... hand grenades? ... RPG's?

    2. Re:cue Tom Sellek : by viperidaenz · · Score: 1

      3D printed a hand grenade? Where do you get the detonator and explosive from? The rest of it is just metal. It can simply be a tin can filled with nuts and bolts.
      As soon as complex compounds can be assembled by a printer.... Well you're in Startrek's universe then

    3. Re:cue Tom Sellek : by PolygamousRanchKid+ · · Score: 1

      Where do you get the detonator and explosive from?

      From the cabinet beneath your kitchen sink.

      Or in your bathroom closet, where you keep your cleaning stuff.

      Or a big jar of iodine crystals and a bottle of ammonia.

      There are still a few minor "stability" issues with that last one.

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    4. Re:cue Tom Sellek : by bkmoore · · Score: 4, Informative

      ....Never mind if we ever get to a point where you can 3D print your own AK-47 that can fire 30k rounds without the receiver breaking or the barrel exploding in your face like the original can or ... hand grenades? ... RPG's?

      You could make small arms with conventional machine-shop tools. Why is this always an issue when people talk about 3d printing??? No-one is saying, "if you let people buy a hobby lathe, they could start turning out hand grenades and rifle barrels."

    5. Re:cue Tom Sellek : by Anonymous Coward · · Score: 1

      You obviously aren't familiar with manufacture efficiencies. You will never be able to be as efficient as a manufacturing plant that churns out the same part every 5 seconds from cheap raw materials.

      3D printing is, and always will be for specialized parts in limited quantities. If it is a large enough market, they will makes molds and dies so they can produce the part faster and cheaper. It's called economies of scale.

    6. Re:cue Tom Sellek : by hackertourist · · Score: 1

      "if you let people buy a hobby lathe, they could start turning out hand grenades and rifle barrels

      So true. I bought a hobby lathe for use in scale modelling, and (even though I've never owned a gun) I now feel the irresistible urge to turn nothing but gun barrels. I am hackertourist, and I am an addict.

  8. Blame Andy Wier. [Re:Science is a verb now?] by XXongo · · Score: 1
    Blame Andy Weir. It's a quote from The Martian: "I'm going to science the shit out of this":

    three-second youtube clip

    And here's Obama saying it: https://www.youtube.com/watch?... (about 1 minute in. But he modifies the line to "going to science the heck out of this").

  9. 3d pirate bay by captbollocks · · Score: 1

    I can't wait for a torrent where I can just download the plans and print out a 911 turbo.

    1. Re:3d pirate bay by DontBeAMoran · · Score: 1
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    2. Re:3d pirate bay by amiga3D · · Score: 1

      This is a little more practical maybe. https://en.wikipedia.org/wiki/...

  10. Re:Gay! by DontBeAMoran · · Score: 3

    You only know about PLA and you apply that knowledge to everything that says "3D printed".

    Fascinating.

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  11. Re:They don't drive those cars. by coolmoe2 · · Score: 1

    Completely valid life choice there. Don't judge them. :P

  12. Re:Why did they destroy the old tooling? by amiga3D · · Score: 2

    You can always sell old tooling to retro parts makers.

  13. Re:Obama's fault? REALLY? by amiga3D · · Score: 1

    Good point. This constant need to drag politics into every single discussion is beyond annoying.

  14. Isn't it engineering" by hawguy · · Score: 1

    They'll science something for you.

    This sounds more like engineering than science -- 3d printers and laser heating sounds more like an application of engineering than science.

  15. Re:Why did they destroy the old tooling? by adolf · · Score: 1

    There's a ridiculous amount of money in supporting hundreds of rare, valuable cars.

    If there are thousands and millions of examples, you've got competition: Everyone and their brother will be making parts that compete with your own. Hundreds, though? That's a captive market and you can name your price.

  16. the unabomber built pipe ones in his small shack by Joe_Dragon · · Score: 1

    the unabomber built pipe ones in his small shack with no grid power

  17. Finally!!! by zifn4b · · Score: 3, Insightful

    I can finally get parts for my Porsche collection said no Slashdot member ever.

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    1. Re:Finally!!! by Anonymous Coward · · Score: 1

      As a Porsche owner and PCA member, I can verify that the prices are outrageous. My half shafts cost over $400 each, but I purchased the exact same items for a VW bus for $80 each. The OEM A/C slider knobs are $30 each, and the rubber sunroof seal is $120. The A/C compressor was $600 and was stamped Denso.

      I have learned quite a bit, and have performed much of the maintenance myself. Rebuilt power steering was ridiculous, but I did my own for $80 worth of seals (still a ripoff for o-rings).

  18. Re:the unabomber built pipe ones in his small shac by viperidaenz · · Score: 1

    Exactly. 3D printing doesn't really offer anything for bomb makers. Except for having them spend a lot of money for something that provides no tangible benefit.

    and sintered metal isn't ever going to be as strong as forged for making guns.

  19. Specialised tools by Bert64 · · Score: 1

    Clearly the specialised tools existed at the time the car was manufactured, so why do these tools no longer exist? Were they destroyed?
    Surely it would make sense to keep such things for production of classic parts, especially for a manufacturer like Porsche.

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  20. Re:Gay! by slacktide · · Score: 1

    Cobalt Chromium is one of the most frequently printed metals. It is being widely used for 3D printed medical implants. https://en.wikipedia.org/wiki/...

  21. IP Laws by DrYak · · Score: 1

    Depends.

    If he would be trying to *sell* the parts for a profit on some eBay-liexpress-mazon website :
    Yes, he would be probably infringing some patents and/or trademarks.
    That's not different from current chinese crappy-cheap knock offs sold on the same site.
    Except that the guy is probably located in a jurisdiction where enforcing IP rights would be easier for Porsche.

    If he is building them himself to use them :
    Nope fat chance. In most sane jurisdiction, 3D printing his own parts to repair a car would fall under the same situation as making some elements out of acrylic/plywood/moldign them himself/cutting the metal, etc.
    As long as the vehicle still passes inspection and is considered streetworthy, it's okay.

    The laws would need to be changed.
      - trying to bring some new **AA-like laws to make home printing illegal. (But goodluck enforcing it, short of passing a law making mandatory to register every single 3D printer, including self-made ones). <- I still see this as a probability, but coming more with "Think of the children !" hysteria regarding home printing of weapons.
      - trying to make "streetworthiness criteria" much more stringent and to refuse any part that isn't provided (3d printed or not) by the original manufacturer. <- this looks to me as a liekly scenario, specially in IP lawsuit happy jurisdictions like the US.

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  22. We also need a plastic part database by hawk · · Score: 1

    I have a 1972 Eldorado convertible. It doesn't have excessive plastic, but some parts, such as the molding next to the back seat, which also holds the latch for the parade boot, are showing their age (and then some: that part showed it by disintegrating when I tuned the latch).

    Being able to print these would be a big deal. Cadillac isn't going to make any more, and it would be prohibitively expensive if they did. But if a straightforward ways mad to scan these, printing would be a truly desirable option.

    hawk

  23. Re:No they won't by hipp5 · · Score: 1
    Which is why TFS mentions that they are 3D printing nine

    parts. I.e. the parts that don't have extreme strength requirements, don't need to be uber precise, and don't need to be made of an alloy that 3D printers don't use...

  24. Best by avawhite009 · · Score: 1

    This is a little more practical maybe. http://www.weybridgeusedcars.c...