DBO - Design Build Optimise

Design, Fabrication and 3D printing by Rushil Kisoon

Photos from DBO - Design Build Optimise's post 24/12/2022

๐—–๐˜‚๐˜€๐˜๐—ผ๐—บ ๐—ง๐—ผ๐˜†๐—ผ๐˜๐—ฎ ๐—–๐—ผ๐—ฟ๐—ผ๐—น๐—น๐—ฎ ๐—ฅ๐—ซ๐—ถ ๐—š๐—ฟ๐—ถ๐—น๐—น๐—ฒ ๐—•๐—ฎ๐—ฑ๐—ด๐—ฒ
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I was recently requested to create a grille badge for a Toyota Corolla RXi.

It makes use of a hidden sandwich plate mount. This allows the badge to fit perfectly between the grille slots whilst still being securely fastened with two screws.
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Printer: Ender 5 Pro
Filament: CCTREE PETG Black, PLA Red, PLA Silver
Nozzle: 0.4
Layer Height: 0.12
Slicer: Cura 5
Link:
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Photos from DBO - Design Build Optimise's post 12/10/2022

๐—–๐—ผ๐—ฟ๐—ผ๐—น๐—น๐—ฎ ๐—•๐—ผ๐—ผ๐˜ ๐—ฆ๐—ฝ๐—ผ๐—ถ๐—น๐—ฒ๐—ฟ ๐—•๐—ฟ๐—ฎ๐—ธ๐—ฒ ๐—Ÿ๐—ถ๐—ด๐—ต๐˜ ๐—Ÿ๐—˜๐—— ๐—ฅ๐—ฒ๐—ฝ๐—น๐—ฎ๐—ฐ๐—ฒ๐—บ๐—ฒ๐—ป๐˜
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After 20 years of use, some of the brake light LEDs failed, whilst others lost significant brightness.
New brake light assemblies were far too expensive when the only issue were the LEDs.
Each resistor and LED was replaced and soldered to restore the original brightness of the brake light.
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Photos from DIYElectronics's post 06/08/2022

Being able to reproduce rare and out of production car parts is one of the main upsides to 3D printingโ€ฆ The satisfaction when a part as complex as this, lines up and clips in, is incomparable.

Photos from DBO - Design Build Optimise's post 02/08/2022

๐—ฆ๐—ฒ๐—น๐—ณ-๐—Ÿ๐—ฒ๐˜ƒ๐—ฒ๐—น๐—น๐—ถ๐—ป๐—ด / ๐—™๐—น๐—ผ๐—ฎ๐˜๐—ถ๐—ป๐—ด ๐—ช๐—ต๐—ฒ๐—ฒ๐—น ๐—–๐—ฒ๐—ป๐˜๐—ฟ๐—ฒ ๐—–๐—ฎ๐—ฝโ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”
I didnโ€™t like the look of the included centre caps, so I decided to make new ones. The plan was to just have a Toyota logo, but after finding a fidget spinner in my room, the idea slowly developed into the Rolls Royce style cap, which has a weighted, self-levelling, logo.

The design process involved a few iterations, since the tolerances were so fine. The final assembly consisted of 6 parts. The centre cap, the new spinning cap, the logo, a bearing, the bearing mount and the bearing cover.

The central hole of the included cap was used to mount the bearing holder, with some epoxy, whilst allowing the shaft of the cap to pass through.

606 ZZ bearings were used, but after some initial testing the grease within them proved to be too viscous to allow the cap to spin freely. Subsequently the grease was removed and replaced with a coating of Q5 graphite spray.

Improvements can be made, such as the use of sealed or ceramic bearings, but as a proof of concept, the idea seems to work well.
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Printer: Ender 5 Pro
Filament: CCTREE PETG Black, PLA Gold
Nozzle: 0.4
Layer Height: 0.12
Slicer: Cura 5
Link: https://www.thingiverse.com/thing:5446290
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Photos from DBO - Design Build Optimise's post 10/05/2022

๐—ง๐—ผ๐˜†๐—ผ๐˜๐—ฎ ๐—ฃ๐—ฎ๐—ป๐—ฒ๐—น ๐—–๐—น๐—ถ๐—ฝ: ๐Ÿต๐Ÿฌ๐Ÿฐ๐Ÿฒ๐Ÿณ-๐Ÿฌ๐Ÿณ๐Ÿฎ๐Ÿญ๐Ÿญ
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These panel clips are almost designed to fail upon removalโ€ฆ So instead of purchasing new ones with the same weak points, redesigning them in SolidWorks allowed for improvements to be made.

Various iterations were designed and tested for strength and durability, before being printed in PETG.
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Printer: Ender 5 Pro
Filament: CCTREE PETG Black
Nozzle: 0.4
Layer Height: 0.12
Slicer: Cura 4.13
Link:
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Photos from DBO - Design Build Optimise's post 27/03/2022

๐—ง๐—ผ๐˜†๐—ผ๐˜๐—ฎ ๐—ฆ๐˜๐—ฒ๐—ฒ๐—ฟ๐—ถ๐—ป๐—ด ๐—ช๐—ต๐—ฒ๐—ฒ๐—น ๐—˜๐—บ๐—ฏ๐—น๐—ฒ๐—บ/๐—Ÿ๐—ผ๐—ด๐—ผ/๐—•๐—ฎ๐—ฑ๐—ด๐—ฒ โ†’โ†’โ†’
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This style of Toyota steering wheel has the logo printed onto a metal disk, possibly through dye sublimation.
After years of use, the dye wears away, revealing the shiny metal underneath.

Since the badge is part of the airbag assembly, it is not sold separately. Subsequently, a 40 mm logo was designed and printed to fit over the worn part.
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Printer: Ender 5 Pro
Filament: CCTREE PLA Black and Silver
Nozzle: 0.4
Layer Height: 0.16
Slicer: Cura 4.13
Link:
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Photos from DBO - Design Build Optimise's post 26/02/2022

๐—–๐—ผ๐—ฟ๐—ผ๐—น๐—น๐—ฎ ๐—š๐—ง ๐—๐——๐—  ๐—˜๐—บ๐—ฏ๐—น๐—ฒ๐—บ๐˜€
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The Corolla and GT JDM style badges were recreated to add an OEM touch.

The original gel sticker emblems that came on models were underwhelming when compared to proper 3-dimensional emblems.

They were printed in various colours and adhered to the rear boot lid, as well as the front fenders, as originally intended.

Part numbers:
75442-1A370
75351-12060
75444-1A440
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Printer: Ender 5 Pro
Filament: CCTREE PLA Gold, Silver & Black
Nozzle: 0.4
Layer Height: 0.16
Slicer: Cura 4.11
Link:
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Photos from DBO - Design Build Optimise's post 26/02/2022

๐—–๐—ผ๐—ฟ๐—ผ๐—น๐—น๐—ฎ ๐—š๐—ง ๐—๐——๐—  ๐—˜๐—บ๐—ฏ๐—น๐—ฒ๐—บ๐˜€
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The JDM style Corolla and GT badges were recreated to add an OEM touch.

The original gel sticker emblems that came on models were underwhelming when compared to proper 3-dimensional emblems.

They were printed in various colours and adhered to the rear boot lid, as well as the front fenders, as originally intended.

Part numbers:
75442-1A370
75351-12060
75444-1A440
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Printer: Ender 5 Pro
Filament: CCTREE PLA Gold, Silver & Black
Nozzle: 0.4
Layer Height: 0.16
Slicer: Cura 4.11
Link:
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Photos from DBO - Design Build Optimise's post 22/02/2022

๐—•๐— ๐—ช ๐—ญ๐Ÿฐ ๐—š๐Ÿฎ๐Ÿต ๐—ฅ๐—ฒ๐—ฎ๐—ฟ ๐—˜๐—บ๐—ฏ๐—น๐—ฒ๐—บ โ†’โ†’โ†’
๐—•๐— ๐—ช ๐—ฃ๐——๐—–
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The new G29 Z4 rear emblem is much more modern looking than the previous generations.
The emblem was modelled and printed for , finished in gloss black.

A set of PDC blanks were also created, which clip into the OEM mounting brackets.
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Printer: Ender 5 Pro
Filament: CCTREE PLA
Nozzle: 0.4
Layer Height: 0.12
Slicer: Cura 4.13
Link:
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Photos from DBO - Design Build Optimise's post 20/02/2022

๐—™๐˜‚๐—ฒ๐—น ๐—–๐—ฎ๐—ฝ ๐—›๐—ผ๐—น๐—ฑ๐—ฒ๐—ฟ - ๐—”๐—˜๐Ÿญ๐Ÿญ๐Ÿญ ๐—–๐—ผ๐—ฟ๐—ผ๐—น๐—น๐—ฎ โ†’โ†’โ†’
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I was always curious as to why there was a notch in the fuel doorโ€ฆ turns out that it is the perfect place to mount a petrol cap holder.

The best part, it fits perfectly in the gap when the door is closed.
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Photos from DBO - Design Build Optimise's post 19/02/2022

๐—ฉ๐—ฎ๐—น๐˜ƒ๐—ฒ ๐—ฆ๐˜๐—ฒ๐—บ ๐—–๐—ฎ๐—ฝ
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The old valve stem caps were cracked and lost their threads. Instead of replacing it with the standard style, a set of caps with the Toyota logo were printed out.

A layer change was done before the logo, allowing a contrasting colour to be seen, in this case, gold.
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Printer: Ender 5 Pro
Filament: CCTREE PLA - Black & Gold
Nozzle: 0.4
Layer Height: 0.16
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Photos from DBO - Design Build Optimise's post 18/02/2022

๐—–๐—ผ๐—ฟ๐—ผ๐—น๐—น๐—ฎ ๐—ฅ๐—ฒ๐—บ๐—ผ๐˜๐—ฒ ๐—•๐˜‚๐˜๐˜๐—ผ๐—ป ๐—ฅ๐—ฒ๐—ฝ๐—น๐—ฎ๐—ฐ๐—ฒ๐—บ๐—ฒ๐—ป๐˜
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Many years of wear and tear have deteriorated the button on the remote for the alarm.

This part is long out of production, so I decided to recreate it using TPU.
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Printer: Ender 5 Pro
Filament: CCTREE TPU
Nozzle: 0.4
Layer Height: 0.12
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Photos from DBO - Design Build Optimise's post 06/11/2021

๐—œ๐—ฟ๐—ผ๐—ป ๐— ๐—ฎ๐—ป, ๐—ฃ๐—ฎ๐—น๐—น๐—ฎ๐—ฑ๐—ถ๐˜‚๐—บ ๐—”๐—ฟ๐—ฐ ๐—ฅ๐—ฒ๐—ฎ๐—ฐ๐˜๐—ผ๐—ฟ ๐— ๐—ฎ๐—ฟ๐—ธ ๐—œ
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โ†’โ†’โ†’ Swipe to power down.

The instantly recognisable arc reactor from Iron Man 1.

A mixture of white and blue LEDs, created the cyan hue, whilst being powered by USB.

Copper wire wound around the outer ring completes the Industrial look.
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Printer: Ender 5 Pro
Filament: CCTREE ABS, PLA
Nozzle: 0.4
Layer Height: 0.2
Slicer: Cura 4.11
Link: thing:2069812
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Photos from DBO - Design Build Optimise's post 25/10/2021

๐—ฆ๐—ฒ๐—ฐ๐—ผ๐—ป๐—ฑ๐—ฎ๐—ฟ๐˜† ๐—ฃ๐—ฎ๐—ฟ๐—ธ ๐—Ÿ๐—ถ๐—ด๐—ต๐˜ ๐—•๐˜‚๐—น๐—ฏ ๐—›๐—ผ๐—น๐—ฑ๐—ฒ๐—ฟ - ๐—”๐—˜๐Ÿญ๐Ÿญ๐Ÿญ ๐—–๐—ผ๐—ฟ๐—ผ๐—น๐—น๐—ฎ
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DesIgn and fabrication of bulb holders for .rolla
Adding the extra park light bulb both completes the JDM look, as well as improves on safety. Since the lights were designed for this feature, but was not included on South African models, it was a simple retrofit.

PETG was used to ensure that the holder was able to maintain its form despite the heat from the bulb.
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Printer: Ender 5 Pro
Filament: CCTREE PETG - Black
Nozzle: 0.4
Layer Height: 0.2
Slicer: Cura 4.8
Link:
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Photos from DBO - Design Build Optimise's post 30/06/2021

๐—™๐˜‚๐—ฒ๐—น ๐—–๐—ฎ๐—ฝ ๐—›๐—ผ๐—น๐—ฑ๐—ฒ๐—ฟ - ๐—”๐—˜๐Ÿญ๐Ÿญ๐Ÿญ ๐—–๐—ผ๐—ฟ๐—ผ๐—น๐—น๐—ฎ โ†’โ†’โ†’
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Some close up pictures of the fuel cap holder from the previous post. rolla
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Printer: Ender 5 Pro
Filament: CCTREE PLA - Black
Nozzle: 0.4
Layer Height: 0.2
Slicer: Cura 4.8
Link:
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๐—ฆ๐—ฒ๐—น๐—ณ-๐—Ÿ๐—ฒ๐˜ƒ๐—ฒ๐—น๐—น๐—ถ๐—ป๐—ด/๐—™๐—น๐—ผ๐—ฎ๐˜๐—ถ๐—ป๐—ด ๐—–๐—ฒ๐—ป๐˜๐—ฟ๐—ฒ ๐—–๐—ฎ๐—ฝ๐˜€โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€”โ€” I didnโ€™t like the look of the included centre caps, so I decide...

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