Custom Go Cart Parts created by 3D Scanning and 3D Printing in Sydney, NSW

Creating custom parts for replica vehicles often requires more than simply finding an off-the-shelf component. In this project, a custom wheel cap and BBS-style wheel insert were designed for a go-kart replica of a Formula 1 car, with the aim of making the wheels closely resemble those of a full-size race car.

The Project

The client was building a go-kart replica inspired by a Formula 1 car and wanted the wheels to have a more authentic appearance. The existing go-kart wheels did not match the desired design, so a custom BBS-style wheel insert and hub cap was required. The new components needed to fit over the existing wheels while maintaining the correct proportions and appearance of the replica.

Step 1: 3D Scanning the Existing Wheel

The existing wheel was 3D scanned to accurately capture its dimensions and geometry. The scan provided a digital reference of the wheel, allowing the new components to be designed around the actual wheel rather than relying on estimated measurements. This was particularly important for achieving a secure and accurate fit.

Step 2: Designing the Custom BBS-Style Insert

The scan data was combined with a 2D reference image of the desired wheel design. Using both sources, the hub and BBS-style rim insert were modelled in CAD. The design was developed as a two-piece system, allowing the components to be manufactured separately while fitting together correctly once installed on the wheel. The 3D scan established the physical dimensions and mounting geometry, while the reference image was used to reproduce the desired visual appearance.

Step 3: 3D Printing the Custom Parts

Once the CAD design was completed, the components were 3D printed and assembled to check the fit. The scan-based design allowed the printed parts to be matched closely to the original wheel, reducing the need for trial-and-error fitting.

The Finished Result

The completed wheel insert and hub were supplied to the client and fitted over the existing go-kart wheel. The result gave the replica a much more authentic appearance while retaining the original wheels underneath. The custom parts were designed specifically around the scanned wheel, providing a precise fit without requiring modifications to the original wheel.

Custom 3D Scanning and CAD Design

This project demonstrates how 3D scanning, CAD modelling and 3D printing can be combined to create custom components for vehicles and private projects. 3D scanning is particularly useful when designing parts that need to fit an existing object, as the physical geometry can be captured directly and used as the foundation for a custom design. The same approach can be used for automotive parts, restoration projects, custom vehicle components, replica vehicles, marine applications, prototypes and other bespoke projects where an accurately fitted custom part is required.