Project Portfolio
Every part, prototype and page of this website was built and run by me. This portfolio is here to give you an honest insight into how I work and what goes into some of the parts that come out of my workshop. You'll find finished projects alongside experiments and the ones that didn't make the cut, because I think the full picture is more interesting than just the highlights.
Horn Reproduction
The client provided the original horn and requested a reproduction, with particular attention to the raised bump around the rim.
The original part was 3D scanned and reverse engineered in Fusion. To preserve the requested rim detail while minimising surface artifacts, the horn was split into two components and bonded post print
The part was successfully reproduced in FDM. Refinement is ongoing using a temperature resistant resin to improve detail fidelity and reduce post processing
Vacuum Forming Experimentation
This project explored the feasibility of reproducing period correct armrests using a printable foam and vinyl targeting a finish that matches the factory original in both appearance and feel.
An original AP6 armrest was 3D scanned and reverse engineered in Fusion, producing two variants, a faithful reproduction of the original geometry, and a modified buck designed for forming vinyl prior to transfer onto the printed foam copy. The same process was applied to the 3-spoke horn pad
The geometry of the arm pad proved to be the most significant challenge of this process, forming the vinyl cleanly around the curves without introducing visible tears or wrinkles required considerable time and technique. Concealing the vinyl beneath the armrest and horn pad added a further layer of difficulty, as the geometry left little room to hide seams without affecting the finished appearance and fit. Taken together, these factors make this particular part near the upper limit of what this method handles well. That said, the workflow has potential for less complex or detailed pieces.