New spare parts for classic cars

Kirchheim/Teck, September 18, 2024. Classic cars are a true passion – and often a valuable investment. When an engine fails, not only is the driving pleasure gone, but so is the vehicle’s value. Retro-Design 3D GmbH specializes in the design, production, and reproduction of replacement parts for historic vehicles and classic cars. A key partner in this endeavor is the BENSELER subsidiary 3D Laser BW: The specialists in Kirchheim unter Teck use CNC machining to provide high-quality surface finishing for faithful reproductions of components such as cylinder heads, crankcase housings, and oil pumps.

The special appeal of historic vehicles and classic cars is both a blessing and a curse: their age. While it creates fascination, it also becomes a problem when critical components fail and need replacement—because in most cases, they are no longer available. If engine parts are affected, the vehicle often remains off the road entirely, and even million-dollar sports cars can quickly become practically worthless. When a new engine is installed, it must look exactly like the original. This is where Retro-Design 3D GmbH comes in. The company specializes in replacement parts that are rare or no longer available for historic vehicles and classic cars, including parts used for Porsche models such as the Porsche 356 Carrera, Porsche 550 Spyder, Porsche 718, and Porsche 904.

The near-net-shape parts designed and manufactured by Retro-Design 3D—such as cylinder heads, crankcase housings, and oil pumps - are delivered to the production facilities of 3D Laser BW in Kirchheim unter Teck, a subsidiary of the BENSELER Group. There, the raw parts are finish-machined or milled from solid material to create ready-to-install components.

High-precision post-processing and milling from solid material

In raw-part post-processing, the workpiece is further machined after the initial manufacturing step (casting) to smooth surfaces, correct dimensions, or add additional features. Machining post-processing is used to achieve the required properties of the component and improve its final quality. Milling from solid material involves machining a component from a solid block. This process is carried out in multiple steps, with the milling tool gradually removing material until the desired shape is achieved. It is commonly used to produce complex and highly precise parts quickly.

3D Laser BW is capable of producing raw parts on its additive manufacturing (AM) systems and subsequently machining them on a 5-axis milling machine up to a size of 850 x 750 x 550 mm. Upstream and downstream processes are also part of daily operations. Retro-Design 3D then delivers the finished engine components to its customers, who install them in their valuable classic cars.

“We support our customers in the development of their components, regardless of whether they are customer-supplied cast parts or 3D-printed parts produced in-house,” explains Oliver Wagner, Managing Director of 3D Laser BW. “This ensures that downstream processes such as 5-axis machining, heat treatment, and coating deliver optimal results and run smoothly."