At The Parts Generator, we take pride in transforming our customers’ ideas into practical, bespoke 3D-printed solutions. One of our recent projects was designing and producing a precision 3D-printed blanking cover for the 1990-1991 Honda CRX SiR fog lights. This innovative piece not only replicates the functionality of the original orange lens cover but adapts it to meet a customer’s unique requirements. Here’s how we brought this custom design to life.
The Request: A Modern Take on a Classic Design
The original Honda CRX SiR fog lights came with an orange lens cover that could be hinged down over the clear lens to enhance visibility in adverse weather. However, our customer wanted something slightly different—a blanking cover to protect the clear lens when the fog lights weren’t in use.
This request offered an exciting challenge: to create a direct-fitting replacement for the original lens cover but with a clean, modern design that would provide superior protection without compromising on the fit and aesthetics of the CRX’s iconic look.
The Design Process: Blending Functionality with Precision
To create this bespoke solution, we followed a meticulous design process to ensure the blanking cover met the customer’s needs and maintained the high standards The Parts Generator is known for.
- Analysing the Original Lens
We began by examining the original orange lens cover, studying its hinge mechanism, dimensions, and fit. This provided the foundation for designing a replacement that would seamlessly attach to the fog light assembly. - Customising the Design
Using advanced CAD software, we designed a hinged blanking cover that precisely matched the original mounting points. The cover was tailored to protect the clear lens effectively while remaining sleek and unobtrusive when in place. - Material Selection: ASA for Durability
For this project, we chose ASA (Acrylonitrile Styrene Acrylate), a high-performance material known for its weather resistance, UV stability, and strength. ASA was the perfect choice for ensuring the cover could withstand outdoor conditions and remain durable over time. - Prototyping and Testing
Once the initial design was completed, we 3D-printed a prototype to test the fit and functionality. The hinged mechanism was fine-tuned to provide smooth operation, and the cover’s dimensions were adjusted for a snug, secure fit.
The Final Product: A Functional and Stylish Solution
The finished hinged blanking cover perfectly replicates the fit and functionality of the original lens cover, with a modern twist to meet the customer’s specific needs. Here’s why this piece stands out:
- Direct Fit: Designed to match the original mounting points for easy installation.
- Hinged Design: Allows the cover to fold up or down seamlessly when needed.
- Durable Material: 3D-printed in ASA for superior strength, weather resistance, and UV stability.
- Custom Solution: Protects the clear lens when fog lights aren’t in use, keeping them clean and scratch-free.
Why We Love Projects Like This
This project exemplifies what The Parts Generator is all about—creating bespoke 3D-printed solutions that meet our customers’ unique needs. By combining precision engineering with high-quality materials, we’re able to produce functional, durable parts that not only replicate but often improve upon original designs.
Whether you’re restoring a classic Honda CRX or have a custom idea for a unique component, we’re here to help bring your vision to life.
Have a custom part in mind? Get in touch with us today to discuss your project and see how 3D printing can make it a reality!
