PrintedForFun Builds a Carbon Porsche Using QUICKSURFACE

In this project focused on Reverse Engineering Car Exterior from scan data, QUICKSURFACE served as the central engineering tool that connected raw mesh data to fully manufacturable CAD geometry.

Project Vision: Custom Carbon Porsche Exterior

Philipp Kreiser, known online as PrintedForFun, set out to design and build a fully custom Porsche exterior in carbon fiber based on an original chassis — without relying on expensive coachbuilders, which typically charge €750k–€1M. Instead of using traditional foam sculpting methods, he chose a fully digital Scan-to-CAD workflow. He worked from STL scan data and rebuilt the geometry in CAD, enabling controlled surfacing, dimensional validation, and repeatable manufacturing. This approach turned the challenge of Reverse Engineering Car Exterior from STL into a structured engineering process rather than a manual styling exercise.

Step 1: 3D Scanning the Car

The project started with structured data capture of the entire vehicle. Multiple scanners were used throughout the project to capture different levels of detail and accuracy. The Revopoint Miraco Plus with photogrammetry kit produced the initial full exterior baseline scan. The Creality Otter and Sermoon S1 handled interior scans, although some drift occurred due to markerless infrared scanning. For molds and carbon parts, the team used the Revopoint Trackit to achieve high-accuracy, markerless data capture.

Standard infrared scanning introduced accuracy float of up to 1 cm over the full length of the car. By switching to Trackit Scanner, deviation was reduced to sub-0.5 mm, verified through deviation analysis in QUICKSURFACE Pro. Mesh comparisons were evaluated at 0.3 mm tolerance, with most results remaining within 0.1–0.2 mm — sufficient accuracy for producing large carbon body panels.

Step 2: Reverse Engineering Software Choice

After evaluating GOM Inspect, Geomagic, and other tools, the user selected QUICKSURFACE Pro. He chose it for its strong alignment functionality, integrated CAD tools, freeform surfacing capabilities, hybrid modeling workflow, and parametric control — especially improved in version QUICKSURFACE 2026. In the early phase, he completed some CAD steps in Fusion 360 due to limitations in version QUICKSURFACE 2025. With the improvements introduced in version 2026, including enhanced filleting and face move/offset tools, he now keeps more of the work entirely inside QUICKSURFACE. This shift improves workflow continuity and maintains tighter parametric control throughout the reverse engineering process.

Step 3: Design Workflow in QUICKSURFACE

Inside QUICKSURFACE, the design process followed a structured, production-oriented workflow. The team began by aligning and mirroring the scan data to establish symmetry and a clean engineering baseline. They then remeshed the model and validated deviation to ensure the scan accuracy supported downstream surface reconstruction.

Front Fender Redesign in QUICKSURFACE

From there, freeform surface modeling transformed raw mesh data into controlled CAD geometry. Using sketches combined with lofting, the team defined precise transitions and maintained design intent across complex exterior areas. This hybrid modeling approach — combining freeform flexibility with parametric structure — kept the workflow both creative and technically controlled.

Throughout development, thickness and deviation analysis remained active. For example, the team continuously verified a consistent 2 mm carbon thickness to ensure manufacturability and structural reliability. QUICKSURFACE made it possible to validate these parameters directly against the scan, eliminating guesswork before production.

The learning curve was real. Early stages relied heavily on trimmed surfaces, which slowed progress and complicated edits. As experience grew, the workflow improved through creased freeform surfaces and better feature management. Tutorials significantly accelerated this transition.

By the end of the project, efficiency increased dramatically. The final 50% of the design required only 15–20% of the initial effort — clear proof that once the workflow inside QUICKSURFACE is optimized, complex automotive reverse engineering becomes faster, cleaner, and more predictable.

Turn Signal Fitment Validation in QUICKSURFACE

Creating Aero Fin Connection for Custom Porsche Body Kit – CAD functionality of QUICKSURFACE Pro
https://www.youtube.com/watch?v=6X3QV2rZwKM

Step 4: 3D Printing the Body Panels

Instead of CNC foam milling, the team selected large-format 3D printing to gain flexibility and remain independent from external suppliers. This decision allowed full control over iteration speed and part modifications during development.

Printer Choice: Creality K2 Plus

The project used the Creality K2 Plus . The team chose this machine for several practical reasons:

• Stable large-format printing
• Closed-loop motors to avoid layer shifts
• Heated chamber
• 350×350×350 mm build volume
• More reliable performance compared to very large “bed-slinger” printers

This setup provided predictable output across long print cycles.

Fender Back Print

Filament Decision

Material selection focused on cost, post-processing behavior, and thermal performance.

• Approximately 150 kg of PLA+ was used, costing around €6–7/kg
• PETG was rejected due to poor sanding behavior
• Standard PLA was rejected because of low heat resistance
• PLA+ withstands 50–60°C mold temperatures

This balance allowed cost-efficient production while maintaining dimensional stability during mold preparation.

Printing Strategy and Output

The team split large components into printer-sized sections. They used wooden dowels for precise alignment and fully glued the assemblies instead of bolting them, increasing structural stability. Post-processing followed a controlled sequence: sanding, filler application, additional sanding, and clear coat. The final surfaces were suitable for fiberglass mold creation.

Each build plate produced approximately 3.5–4 kg of material over about 24 hours. The system operated at roughly 45 mm³/s volumetric flow rate, enabling steady production without compromising reliability.

3D Printed Porsche Exterior Prototype Designed from 3D Scan Data

Step 5: Mold & Carbon Production

With the master geometry completed, the project moved into mold and composite production.

The workflow followed a clear sequence. First, the team produced a 3D printed master. They then completed surface finishing to prepare it for mold creation. From this master, they built a fiberglass negative mold. Finally, they performed carbon fiber lamination to manufacture the final exterior panels.

To close the loop, future scans using Trackit or other structured light scanners will verify mold accuracy, carbon part deviation, potential warping issues, and overall manufacturing repeatability. This step ensures that the physical carbon components match the digital CAD definition and maintain consistency across production cycles.

Key Design Examples

Several components demonstrate how the digital workflow translated into functional carbon parts.

The team began with door panels and fenders as the first test pieces, using them to validate fitment, surface continuity, and production feasibility. They then developed a custom air intake funnel, built using lofting, offset operations, and controlled trimming to achieve both airflow efficiency and manufacturable geometry.

For performance integration, they redesigned the bumper area to accommodate the intercooler, ensuring proper placement and alignment within the new exterior concept. An OEM turn signal was scanned and directly integrated into the design, maintaining compatibility with factory components while adapting it to the custom bodywork.

Throughout all parts, they performed thickness analysis to confirm structural viability and ensure the carbon components met both mechanical and production requirements.

Result

The final design fully transforms the car’s appearance while remaining grounded in measurable engineering control.

The build includes an integrated Porsche light bar, a custom diffuser with fins, roof modifications, and clearly defined modular panel groups such as fenders, doors, roof sections, and bumper assemblies. Each component was digitally validated against the original scan before moving into physical production, ensuring controlled fitment and manufacturability.

CAD model in QUICKSURFACE

When overlaying the designed parts onto the original scan data, the result shows a fully engineered transformation — not cosmetic add-ons placed over an existing body, but a coherent exterior system built from verified geometry.

The user concludes that without QUICKSURFACE, this project would not have been possible. Traditional CAD software alone could not manage this hybrid scan-based workflow with the same level of alignment control, surfacing flexibility, and deviation validation.

Next Steps

The development phase transitions into controlled production and regulatory validation.

The immediate focus is final mold production, followed by carbon lamination of the complete exterior system. In parallel, the team plans structural interior components to support the modified body architecture.

To make the vehicle road compliant, the project will address TÜV requirements, ensuring that all modifications meet structural and safety standards.

Looking ahead, the workflow will scale into future large projects, including a planned BMW build, applying the same digital Scan-to-CAD methodology refined during this Porsche transformation.

Overall Summary

This project demonstrates what is possible when a complete Scan → Reverse Engineer → 3D Print → Mold → Carbon Production workflow runs inside a single, structured environment — especially in a complex case like Reverse Engineering Car Exterior from scan data.

Whatch some videos foromthis frogect here: https://www.youtube.com/watch?v=6X3QV2rZwKM

Accurate scanning established a dependable baseline. QUICKSURFACE combined freeform surfacing with parametric CAD tools, allowing full control over alignment, deviation, thickness, and manufacturability — all within one continuous workflow. Large-scale 3D printing replaced costly traditional methods, while digital validation ensured every panel was engineered before entering production.

The result is not just a custom Porsche exterior. It proves that even large-scale automotive transformations can move from raw STL scan data to production-ready carbon components with precision, efficiency, and repeatability — powered by QUICKSURFACE.

Try QUICKSURFACE free for 30 days

 

Follow PrintedForFun: Reddit YouTube