UNIVERSITY OF EASTERN AFRICA, BARATON
SCHOOL OF SCIENCE AND TECHNOLOGY
DEPARTMENT OF TECHNOLOGY
SENIOR PROJECT II
COURSE CODE: TCED 442
SENIOR PROJECT WRITE UP ON
Additive Manufacturing and Templated Fabrication
AUTHORS
VICTOR NJUNGE GICHUHI
SGICVI2011
SUPERVISOR
ENG. MISOI
DECLARATION
This research proposal is my original work as to the best of my knowledge not been presented
for a degree on any other university or institution of higher learning for examination or for any
other purpose.
NAME; VICTOR GICHUHI SIGNATURE;
ID; SGICVI2011
DATE; 8th July 2025
DEDICATION
To my families, friends, lecturers and mentors whose encouragement towards achievand support
led me to the project goals and achivement.
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ACKNOWLEDGEMENT
I would like to sincerely appreciate the selfless help and support towards the following
individuals who have assisted me throughout the development of my project.
First, I thank the almighty God for good health and strength. He has gotten me to this far.
I thank my supervisors for their technical assistance during design and development of the
device.
I also like to thank my mentors and friends for the encouragement and support to help not give
up and their ideas on the execution of this project. Thank you.
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Catalog
DEDICATION........................................................................................................................................................ 2
ACKNOWLEDGEMENT......................................................................................................................................... 2
ABSTRACT........................................................................................................................................................... 4
CHAPTER 1.......................................................................................................................................................... 5
INTRODUCTION................................................................................................................................................... 5
PROBLEM STATEMENT........................................................................................................................................ 5
JUSTIFICATION.................................................................................................................................................... 6
OBJECTIVES......................................................................................................................................................... 6
MAIN OBJECTIVE................................................................................................................................................. 6
SPECIFIC OBJECTIVES........................................................................................................................................... 6
1. Design and preparation...................................................................................................................................6
3D pen fabrication...............................................................................................................................................6
1. Detailing and final assembly............................................................................................................................6
SCOPE OF THE PROJECT....................................................................................................................................... 7
CHAPTER TWO.................................................................................................................................................... 8
LITERATURE REVIEW........................................................................................................................................... 8
1. Introduction.....................................................................................................................................................8
2. Additive Manufacturing (3D Printing) in the Automotive Industry..................................................................8
3. The 3D Pen as an Accessible Fused Deposition Modeling (FDM) Tool.............................................................9
4. The Methodology of 2D Template-to-3D Object Construction........................................................................9
5. Conclusion.....................................................................................................................................................10
CHAPTER 3........................................................................................................................................................ 11
METHODOLOGY................................................................................................................................................ 11
Phase 1: Design and Preparation.......................................................................................................................11
2. Objective 2: To construct a physical 3D structural frame from the 2D templates.........................................12
Phase 2: 3D Pen Fabrication..............................................................................................................................13
Testing...............................................................................................................................................................14
Results...............................................................................................................................................................15
CHAPTER 4........................................................................................................................................................ 16
INTRODUCTION.................................................................................................................................................16
SUMMARY.........................................................................................................................................................16
CONCLUSION.....................................................................................................................................................16
RECOMMENDATION..........................................................................................................................................17
CHAPTER 5........................................................................................................................................................ 18
APPENDIX..........................................................................................................................................................18
APPENDIX 1: BUDGET........................................................................................................................................18
REFERENCE........................................................................................................................................................ 19
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ABSTRACT
This project explores the relationship between automotive engineering and 3D printing. It dives
into how this technology is currently revolutionizing vehicle design, prototyping, and production,
while also projecting the future trajectory of 3D printing in car modeling. 3D printing drastically
reduces development time and costs for new components.This allows for more design iterations
and innovations without the high expenses associated with traditional manufacturing.
Furthermore, 3D printing facilitates the creation of complex and lightweight parts that were
previously impossible to manufacture, leading to improved vehicle performance and fuel
efficiency. The technology also offers opportunities for customization, allowing manufacturers to
produce tailored components to meet specific customer requirements.
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CHAPTER 1
INTRODUCTION
The automotive sector is currently experiencing a technological revolution, with 3D printing,
also referred to as additive manufacturing.
This groundbreaking technology is transforming the design, development, and production of
vehicles, evolving from a tool for rapid prototyping into a crucial element of large-scale
manufacturing. This project aims to investigate the significant influence of 3D printing on the
automotive industry, highlighting its role in expediting design and development cycles while
opening up new avenues for vehicle performance and customization.
The adoption of 3D printing has already led to considerable improvements in the automotive
manufacturing process. It facilitates the swift creation of prototypes, allowing designers and
engineers to evaluate and enhance concepts in a fraction of the time and expense associated with
conventional methods. This accelerates the overall development timeline, permitting more design
iterations and resulting in more innovative and superior final products. Additionally, additive
manufacturing is increasingly utilized for producing tooling, jigs, and fixtures, which optimizes
assembly lines and enhances overall manufacturing efficiency.
PROBLEM STATEMENT
Traditional manufacturing techniques for automotive components, including CNC machining,
injection molding, and casting, are facing growing challenges from the requirements of the
contemporary automotive sector. These traditional methods are marked by prolonged lead times,
elevated costs, and considerable restrictions in design complexity, which creates a significant
obstacle to innovation, efficiency, and customization.
A major concern with conventional manufacturing is the considerable time and expense involved
in creating molds, dies, and fixtures for each new component, which is a time-consuming and
costly endeavor that impedes rapid prototyping and design iteration. This lack of flexibility
complicates manufacturers' ability to swiftly respond to market fluctuations or integrate new
design enhancements without incurring substantial expenses and delays.
Moreover, traditional subtractive manufacturing techniques, which involve removing material
from a larger block to form a final part, lead to considerable material waste. This not only poses
environmental challenges but also contributes to the overall production costs. The fundamental
limitations of these methods also constrain the geometric complexity of the parts that can be
manufactured. This complicates the production of lightweight components with complex internal
structures, which are essential for enhancing fuel efficiency and vehicle performance, especially
in electric vehicles.
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The dependence on these conventional methods also creates obstacles to customization and on-
demand production. In a time when consumers increasingly seek personalized products,
traditional manufacturing is ill-equipped for low-volume, customized components. The high
setup costs render it economically impractical to produce small quantities of unique parts. This
situation also impacts the availability of spare parts for older or discontinued models, often
necessitating large, costly inventories.
JUSTIFICATION
In the automotive industry there are many ways of fabricating new part, but most are time
consuming and inefficient. 3D printing changes this by making it easier to create and less energy
is used thus it's good financially and environmentally. 3D printing also gives room for new
materials such as fiber which is made from carbon creating stronger and light weight cars. The
power to weight ratio is greatly reduced saving the economical usage of fuel. The current shift is
able to meet customer demand and at less time.
OBJECTIVES
MAIN OBJECTIVE
To design a car from 2D picture to a 3D frame and use the 3D pen to overlay PLA filament
material to take the shape of the vehicle.
SPECIFIC OBJECTIVES
1. Design and preparation
To develop a set of scaled multiview 2D template views from the front. Side top. And rear
Transfer the scaled 2D templet onto a rigid material like cardboard
CUT out the template shapes and assemble them into a perpendicular interlocking 3D skeleton
that represent the car’s basic form
3D pen fabrication
To master the operational techniques of the 3D pen for structural operations
Calibrate the 3D pen for the optimal temperature and speed for the PLA filament
1. Detailing and final assembly
Use the 3D pen to carefully trace the primary edges of the 3D frame
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Fill the flat and curved surfaces like the bonnet, roof, doors, and fenders by layering the PLA
filament over the structural frame.
Inspect the model for any weakness and reinforce them with additional PLA filament
SCOPE OF THE PROJECT
The scope of the project will include
1. Design and Template Creation: The scope includes the selection of a suitable 2D car
image and the development of scaled, orthographic (front, side, top, rear) templates based
on it. This can be done through digital means or manual tracing.
2. Frame Construction: The project will cover the construction of a physical, non-digital
3D skeleton or jig using basic materials like cardboard or foam board, which will serve as
the foundational structure for the model.
3. 3D Pen Fabrication: The core of the project involves using a 3D pen and Polylactic
Acid (PLA) filament to create the model. This includes tracing the structural frame and
then building up the surfaces and panels layer by layer to form the vehicle's body.
4. Basic Post-Processing: The project will conclude with basic finishing work. This is
limited to trimming excess filament, reinforcing weak structural points, and light sanding
to improve the model's aesthetic quality and ensure it is a cohesive, single piece.
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CHAPTER TWO
LITERATURE REVIEW
1. Introduction
The proposed project, which involves translating a 2D car image into a 3D physical model using
a templated frame and a 3D pen, operates at the intersection of several established fields:
additive manufacturing, rapid prototyping, and hands-on educational modeling. This review
examines the existing literature in these areas to provide a theoretical and practical foundation
for the project. It will first explore the broad impact of industrial additive manufacturing in the
automotive sector, then narrow its focus to the specific technology of 3D pens, and finally,
investigate the methodology of using 2D templates as a guide for 3D construction.
2. Additive Manufacturing (3D Printing) in the Automotive Industry
The adoption of Additive Manufacturing (AM), or 3D printing, has been a transformative force
in the automotive industry for decades. The primary application has been in “rapid prototyping”
as noted by Giffi et al. (2014) in their extensive industry report. AM allows automotive engineers
to produce physical prototypes of new parts in a matter of hours or days, rather than the weeks or
months required by traditional methods like CNC machining or injection molding. This
acceleration of the design-to-prototype cycle allows for more frequent and cost-effective design
iterations, leading to more optimized and innovative final products.
Beyond prototyping, AM has evolved to include the creation of custom tooling, jigs, and fixers.
Companies like Ford and Volkswagen have publicly reported using 3D printing to create custom
tools for their assembly lines, which streamlines the manufacturing process (Schultheiss et al.,
2018). These applications reduce tooling costs and lead times significantly.
More recently, the industry has moved towards printing end-use parts, particularly for high-
performance and luxury vehicles. Materials like carbon-fiber composites and metal alloys are
used to create lightweight yet strong components that would be difficult or impossible to
manufacture conventionally. This practice of "generative design," where software optimizes a
part's geometry for maximum strength and minimal weight, is inextricably linked to AM's ability
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to produce complex shapes (Attaran, 2017). While the project at hand does not use industrial-
grade machines, it fundamentally mimics this core principle: translating a design into a physical,
functional object.
3. The 3D Pen as an Accessible Fused Deposition Modeling (FDM) Tool
The 3D pen is, in essence, a handheld Fused Deposition Modeling (FDM) device. FDM, the
most common form of 3D printing, works by extruding a thermoplastic filament (in this case,
PLA) layer by layer to build an object. A standard 3D printer automates this process based on a
digital CAD file, but a 3D pen places the control directly into the user's hand.
Literature in the educational and maker communities highlights the 3D pen as a powerful tool for
teaching the core concepts of additive manufacturing without the steep learning curve or cost of
traditional 3D printers. As explored by Novotný and Mital (2017) in their study on educational
technologies, 3D pens foster spatial reasoning and provide immediate, tactile feedback. Users
must manually control extrusion speed, temperature, and movement, giving them an intuitive
understanding of how materials behave during the additive process.
The choice of Polylactic Acid (PLA) filament is consistent with standard practices in entry-level
FDM printing. PLA is a biodegradable thermoplastic derived from renewable resources, known
for its low printing temperature, minimal warping, and lack of toxic fumes, making it ideal for a
hands-on, non-industrial setting (Farid, 2016).
4. The Methodology of 2D Template-to-3D Object Construction
The technique of using multi-view 2D drawings (orthographic projections) to define and
construct a 3D object is a cornerstone of engineering, architecture, and art. Historically, this was
how sculptors and model makers would ensure accurate proportions before the advent of digital
tools. This project revitalizes that classic methodology with modern technology.
The process of creating an interlocking "skeleton" or jig from 2D templates is a well-documented
technique in model-making, particularly in the construction of model airplanes and ships. This
structural frame provides a physical roadmap, solving the primary challenge of using a 3D pen:
creating accurate, large-scale structures in open space. Without a guide, drawing in three
dimensions with a pen is imprecise. However, by using the frame, the user is effectively
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"skinning" a pre-defined form. This method transforms the 3D pen from a freehand drawing tool
into a more precise fabrication device.
While formal academic literature on combining 3D pens with structural jigs is still emerging,
numerous case studies within the maker and hobbyist communities demonstrate its viability.
These informal sources show the successful creation of complex objects, from architectural
models to character sculptures, by first building a cardboard or foam armature and then
overlaying it with filament from a 3D pen. This project aims to formalize and document this
effective, low-cost fabrication technique within the context of automotive modeling.
5. Conclusion
This literature review confirms that the proposed project is well-grounded in established
principles while exploring a novel and accessible application of modern technology. It draws
from the high-tech world of automotive additive manufacturing, leverages the educational
potential of 3D pens as FDM tools, and employs a classic, proven methodology of using 2D
templates to guide 3D construction. By synthesizing these areas, the project stands to provide
valuable, practical insights into the fundamental process that underpins all of 3D printing: the
transformation of a design from a two-dimensional concept into a three-dimensional physical
reality.
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CHAPTER 3
METHODOLOGY
Phase 1: Design and Preparation
1. Objective 1: To develop a set of scaled, multi-view 2D templates.
a. Select a high-resolution 2D image of a car that includes clear orthographic views
(front, side, top, and rear).
Figure 1: side orthographic
Figure 2:Top orthographic
b. Manually trace these views onto separate sheets, ensuring they are all scaled
accurately relative to one another.
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Figure 3: 2D template
2. Objective 2: To construct a physical 3D structural frame from the 2D
templates.
a. Transfer the scaled 2D templates onto a rigid material like cardboard, foam board,
or plastic sheets.
b. Cut out the template shapes and assemble them into a perpendicular, interlocking
3D "skeleton" or jig that accurately represents the car's basic form and
proportions. This frame will serve as the physical guide for the 3D pen.
Figure 4:Cut 2D template
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c.
Figure 5:Y and X axis template
d.
Figure 6:3D skeleton template
Phase 2: 3D Pen Fabrication
1. Objective 1: To systematically apply PLA filament to form the main body of the
vehicle.
a. Use the 3D pen to carefully trace the primary edges and contours of the 3D frame,
creating the main "outline" of the car's body.
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Figure 7.:Filled contours with PLA fillament
b. Methodically fill in the flat and curved surfaces (panels) like the hood, roof,
doors, and fenders by layering the PLA filament over the structural frame.
Figure 8:filled surfaces with PLA fillament
Testing
○ Inspect the model for any weak joints or thin panels and reinforce them with
additional PLA filament.
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○ Perform post-processing techniques, such as trimming excess filament strings and
lightly sanding rough surfaces, to achieve a clean and polished final appearance
that accurately reflects the original 2D picture
Results
The structural vehicle is rigid and strong with no warpage. I used a soldering gun to flatten and
remove any holes from the filament overlay.
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CHAPTER 4
INTRODUCTION
Having designed, fabricated and tested our project, it is clear that my objectives have been
achieved though some improvements in design and fabrication can be developed in future. My
main objective was to use additive manufacturing to design and fabricate the body of a vehicle.
The other specific objectives have also been achieved.
SUMMARY
This project successfully demonstrated a low-cost, hands-on methodology for creating a three-
dimensional automotive model from a two-dimensional concept. The process began with the
selection of 2D images of a car, which were then scaled and used to create physical templates.
These templates were assembled into a rigid, interlocking cardboard frame that served as a
structural guide for the fabrication process.
Using a handheld 3D pen loaded with PLA filament, the core of the project involved tracing this
frame. Filament was systematically layered to form the car's primary body panels, including the
bonnet, roof, doors, and fenders. The project concluded with basic refinement to ensure
structural integrity and a clean aesthetic finish, successfully transforming a flat image into a
tangible, physical object.
CONCLUSION
The primary conclusion of this project is that a viable and dimensionally accurate 3D model can
be produced without reliance on expensive industrial machinery. This manual fabrication method
directly addresses the limitations of traditional manufacturing such as high tooling costs by
providing an adaptable alternative for physical prototyping.
The use of a 2D template-to-3D frame technique was a critical success factor. It effectively
bridged the gap between a 2D design and a 3D form, giving the freehand nature of the 3D pen
the essential structure and precision it would otherwise lack. This hybrid approach proves that
combining classic model-making principles with modern, accessible technology can yield
impressive results.
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Ultimately, this project serves as a successful proof-of-concept. It validates that the fundamental
principles of additive manufacturing can be explored and utilized effectively with minimal
resources, democratizing the ability for designers, students, and hobbyists to bring their creative
ideas into tangible reality.
RECOMMENDATION
The department should kindly provide a 3D printer which can be integrated with the AUTO
CAD lessons and labs. This prepares the students for the new technological advancement in the
world so as not to be ill prepared. Thank you.
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CHAPTER 5
APPENDIX
APPENDIX 1: BUDGET
S/No Item name Description Unit Quantity Total cost
Cost (Ksh)
(Ksh)
1 Cardboard Re-used from head gasket 00 4 00
cardboards which are thin
and strong
2 PLA filament 1.75 mm diameter 3,200 1kg 3,200
3 3D printing Supports PLA 4,800 1 4,800
pen
4 Soldering gun 240v 300 1 300
40W
Total (Ksh) 8,300
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REFERENCE
1. Attaran, M. (2017). The rise of 3-D printing: The advantages of additive manufacturing
over traditional manufacturing. Business Horizons, 60(5), 677-688.
2. Farid, N. (2016). A review on the applications of 3D printing in the automotive industry.
International Journal of Mechanical, Aerospace, Industrial, Mechatronic and
Manufacturing Engineering, 10(7), 1270-1275.
3. Giffi, C. A., et al. (2014). 3D opportunity in the automotive industry: Additive
manufacturing and its impact. Deloitte University Press.
4. Novotný, R., & Mital, D. (2017). The Use of 3D Pen in Education. In Proceedings of the
9th International Conference on Computer Supported Education (CSEDU 2017), 2, 441-
446.
5. Schultheiss, F., et al. (2018). Additive manufacturing in the automotive industry.
Springer Vieweg.
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