Case study research: Optical digitization, reverse engineering and rapid prototyping as a solution in pedal car development process

Abstract

The motivation of this work was to find an appropriate manufacturing method for pedal car accessories. This study describes the application of optical digitization, reverse engineering and rapid prototyping in manufacturing process of accessories for handmade pedal car, which imitates an unique historic Czech car, a Škoda 1000 MB, type 990 Roadster. Two well-known design elements, rear light and front indicator, were digitized by non-contact 3D scanner. The digitized 3D models were used as an inputs for reverse engineering. Their shapes were modified due to technological limits of vacuum forming, scaled and used to design of the 3D printed vacuum forming moulds. The final parts were made of transparent foil, trimmed around the perimeter and airbrushed from the inside. The described process served to verify the manufacturability of these accessories before commencing works on a mass-produced pedal cars intended for sale to customers.