3D Printing

Getting started with 3D Printing for race car parts

Here is our experience with 3D Printers and race car parts. Watch the video below covering a large number of topics. If you want an executive summary:

- Get a Bambu Lab H2 series printer

- Use PLA for prototyping, PA6-CF for engine bay components, ASA for exterior parts, TPU for mud flaps, ABS for interior parts (maybe PETG depending on use case).

- Get a Sovol SH03 Dry Box to dry filament and anneal PA6-CF:  https://amzn.to/3QQSpqY  

Our list of recommended products can be found here (look for the 3D printing section):

https://www.frogracing.us/store/recommended-products#h.nkm22fojgsva 

Which filament to choose?

Use PLA for prototyping, PA6-CF for engine bay components, ASA for exterior parts, TPU for mud flaps, ABS for interior parts (maybe PETG depending on use case).

Theis3D Printer Filament Comparison Guide is pretty helpful:  https://bambulab.com/en-us/filament/guide 

Here is the list of filaments we have been using with success (the few ones that did not work are also mentioned):"

• PLA

  • SUNLU PLA+2.0 for rapid prototyping: https://amzn.to/4ev2eCL 

  • FlashForge Rapid PLA: https://amzn.to/4wG6LdG 

  • Multicolor Silk PLA: https://amzn.to/4fydsbB 

  • Dual color PLA (requires an adapter on the spool to not slip in the AMS): https://amzn.to/4xzfFtx 

  • Glow in the dark Green PLA (avoid other colors, green is the only one that works): https://amzn.to/4xzfFtx 

• PETG

  • SUNLU PETG: https://amzn.to/4pOafrI 

• ABS

  • SUNLU High Speed ABS: https://amzn.to/4uPJl3N 

  • Overture ABS Glow Green: https://amzn.to/4g7kC6E 

  • Do not buy Creality ABS, could not get a single correct print

• TPU 95A

  • SUNLU : https://amzn.to/4hHSWXa 

  • Sovol: https://gpx.studio/app 

• ASA

  • Overture black: https://amzn.to/45xN8Iv 

  • Polymaker Pink: https://amzn.to/4hN6uAG 

  • Got bad results from TINMORRY ASA-CF, printed fine but weaker than regular ASA

• Nylon

  • SUNLU PA6-CF: https://amzn.to/4gurxYe 

  • Could not get a decent print with SUNLU Easy PA

Printing PA6-CF

SUNLU PA6-CF (https://amzn.to/4gurxYe ) prints pretty easily with the default PA6-CF from the Bambu slicer. However you will need an AMS-HT or an equivalent filament heater/drier (see recommended products at the bottom of this page).  Plan on at least 8 hours of heating/drying before use and another 8-12hrs of annealing post print to cure the prints of any moisture. 

Printing TPU

TPU 95A can be used to print bushings but it is really out material of choice for mud flaps. The filament cannot be fed through the standard AMS or PTFE tubes to the extruder as it will stretch the filament. We recommend using the SUNLU S4 3D Printer Filament Dryer (https://amzn.to/4wJKOtS) to feed directly to the extruder and keep temperature and moisture under control for your filaments.

Also check out the Bambu Lab TPU Printing Guide: https://wiki.bambulab.com/en/knowledge-sharing/tpu-printing-guide 

The information for the top feeding rack can be found here: https://wiki.bambulab.com/en/h2/h2d-tpu-printing-guide 

Custom Mud Flaps

We tried different material with PETG being too brittle, ABS doing ok but still britlle and not holding to the weather int he long term so TPU 05A is the best bet so far to build your custom mud flaps (video to come soon).

Audi RS4 front splitter and louvers

After the fog light delete we needed to build new custom louvers for the side radiators and we also built a copy of the front splitters with stronger spacers. All the parts were printed in pink ASA for the Women in Motorsports record attempt at Climb to the Clouds 2026!

Email us at info@frogracing.us if you want a print of these models or a copy of the STL files.

Subaru Air intake box

We designed an airbox for aftermarket cold air intake that use a cone style air filter. The box insulates from the hot air of the engine bay and it also provides a drain for any water that would make its way into the intake.

Wheel plugs

We developped a number of custom wheel plugs for Audi RS4 wheels and also Enkei wheels in Subaru fitment. The models will be released soon on Makerworld.

Our free 3D models

Tuff Jug fast flow funnel for stock gas tanks

This funnel allows you to use a Tuff Jug fast flow gas can in a stock car tank filler neck without the restrictive spout adapter extension.

The use of the funnel is demonstrated in the VP Racing vs Tuff Jug video (see below)

Free model available at: https://makerworld.com/en/models/2634605-tuff-jug-fast-flow-funnel-for-stock-gas-tanks#profileId-2909910 

Carbon fiber hood strut

When using a carbon fiber hood, you cannot use the stock hood strut that is too strong. This foldable hood strut is a lightweight solution to prop your carbon fiber hood. This was tested on a 2007 Audi RS4 with a VIS Racing carbon fiber vented hood.

Free model available at: https://makerworld.com/en/models/3118478-audi-rs4-carbon-fiber-hood-strut#profileId-3517612 

RS4 front splitter

This is a replacement for the front splitter on the Audi B7 RS4. You will need to drill holes for the exact fitment of the bolts with your bumper.

We are using M6 bolts with U-nuts to secure the aplitter to the bumper. The model includes 2 snap in covers for the center bolts that can be trimmed down to the needed size depending on the spacing you want between the bumper and the splitter. Check the video below for installation instructions

List of products related to this item:

• 20Sets M6-1.0 Bolts & U-Nuts Assortment: https://amzn.to/4bZ0vp6 

• Gorilla 2 Part Clear Epoxy, 0.85 Ounce Syringe - 5 Minute Set: https://amzn.to/4zr0FPO 

• Vertical Heat Set Insert Tool Press for Plastic Parts & 3D Print Components: https://amzn.to/4xICSJv 

• Brass Threaded Inserts M2 M2.5 M3 M4 M5 M6 for 3D Printing: https://amzn.to/4g7JeMU 

Free model available at: https://makerworld.com/en/models/3188414-audi-b7-rs4-front-splitter#profileId-3606864  

Recommended products

Printers/Scanners

• Bambu Lab H2S for large functional parts in single color: https://us.store.bambulab.com/products/h2s 

• Bambu Lab H2D for multicolor/multi-material prints with AMS Combo: https://us.store.bambulab.com/products/h2d 

• Revopoint MetroX 3D Scanner: https://amzn.to/4uPJl3N 

Filaments

• PLA

  • SUNLU PLA+2.0 for rapid prototyping: https://amzn.to/4ev2eCL 

  • FlashForge Rapid PLA: https://amzn.to/4wG6LdG 

  • Multicolor Silk PLA: https://amzn.to/4fydsbB 

  • Dual color PLA (requires an adapter on the spool to not slip in the AMS): https://amzn.to/4xzfFtx 

  • Glow in the dark Green PLA (avoid other colors, green is the only one that works): https://amzn.to/4xzfFtx 

• PETG

  • SUNLU PETG: https://amzn.to/4pOafrI 

• ABS

  • SUNLU High Speed ABS: https://amzn.to/4uPJl3N 

  • Overture ABS Glow Green: https://amzn.to/4g7kC6E 

  • Do not buy Creality ABS, could not get a single correct print

• TPU 95A

  • SUNLU : https://amzn.to/4hHSWXa 

  • Sovol: https://gpx.studio/app 

• ASA

  • Overture black: https://amzn.to/45xN8Iv 

  • Polymaker Pink: https://amzn.to/4hN6uAG 

  • Got bad results from TINMORRY ASA-CF, printed fine but weaker than regular ASA

• Nylon

  • SUNLU PA6-CF: https://amzn.to/4gurxYe 

  • Could not get a decent print with SUNLU Easy PA

• Storage rack: https://amzn.to/4xIjaPa 

Accessories

• Sovol SH03 Dry Box to dry filament and anneal PA6-CF:  https://amzn.to/3QQSpqY 

• SUNLU S4 3D Printer Filament Dryer ideal for TPU: https://amzn.to/4wJKOtS 

• Bambu Lab AMS HT for high temp filaments: https://us.store.bambulab.com/products/ams-ht 

• Carbon Fiber PEI plate: https://amzn.to/4uVEfmE 

• 3D Scanning spray: https://amzn.to/3QOC1r2 

• Nozzle cleaning/ finishing cutters toolkit: https://amzn.to/44gQa3h 

• Liquid glue for PA6 printing: https://amzn.to/4g7kC6E 

• Glue sticks for PA6 printing: https://amzn.to/4pSJiTJ