Car Dash Kit CAD Design

Project Title:
Custom 3D Printable Dash Fascia – Double DIN + HVAC + Single DIN (2002 Subaru Legacy B4 BE5)

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Project Overview:
I am looking for a 3D designer to create a custom, 3D-printable dash fascia/trim panel for my 2002 Subaru Legacy B4 (BE5 chassis).

The goal is to replace the factory trim with a clean, OEM-style panel that properly fits:
- A double DIN aftermarket head unit
- The factory HVAC control unit
- A single DIN pocket with USB passthrough

This design will be used for real-world installation and 3D printed (PETG, ABS, or ASA), so proper fitment and usability are critical.

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Current Situation:
- The factory trim opening is too small and restrictive
- I have already installed:
- A double DIN head unit (top)
- HVAC controls (middle)
- A single DIN pocket (bottom)
- The single DIN pocket is currently pushed backward, NOT because of mounting limitations, but because the trim opening is too tight to allow everything to sit flush
- The surrounding trim is uneven and does not provide a clean or finished appearance

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Goal Layout (Top to Bottom):
1. Double DIN head unit
2. Factory HVAC control unit
3. Single DIN pocket with USB passthrough

All components should sit flush on the same front plane with no need to recess or offset any parts.

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Key Design Objective (Important):
This is a fitment and clearance problem, not a depth problem.

The design should:
- Provide properly sized and spaced openings
- Eliminate interference from the current tight factory trim
- Allow all components to sit naturally flush
- Not require pushing any components backward to fit

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Design Requirements:

1. One-Piece Dash Fascia (Front Panel):
- A single front-facing panel that replaces the factory trim
- Clean, OEM-style appearance
- Slight bevels or rounded edges preferred (no sharp edges)
- Should fully cover and hide uneven factory trim edges

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2. Component Openings:
- Precision cutouts for:
- Double DIN head unit (~180mm x 100mm standard, allow tolerance)
- Factory HVAC unit (exact measurements will be provided)
- Single DIN pocket (~180mm x 50mm standard)
- Include real-world tolerance (~0.5mm–1mm clearance per side)

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3. Proper Spacing & Alignment:
- Ensure correct vertical spacing between components
- All three components must align flush on the same front surface
- No forced repositioning or interference

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4. Internal Support / Mounting:
- Include basic structure behind the fascia:
- Mounting tabs or support for the single DIN pocket
- Ability to secure the fascia to factory mounting points if possible
- Design should be rigid and not flex easily

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5. USB Integration:
- Include a clean mounting point or cutout for a USB passthrough in the single DIN area
- Flush and integrated look preferred

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6. Material & Print Considerations:
- Designed for FDM 3D printing (PETG, ABS, or ASA)
- Avoid thin or fragile sections
- Recommended thickness: ~3mm minimum
- Must handle automotive interior temperatures

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7. Fit & Finish Goal:
- Final result should look close to OEM, not like a rough 3D printed part
- Smooth surfaces suitable for sanding, priming, and painting

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Deliverables:
- STL file (ready for 3D printing)
- STEP file (editable CAD format)
- Optional: basic render images for visualization

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What I Will Provide:
- Photos of the current dash setup
- Measurements of all components and openings
- Additional reference images if needed

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Timeline:
Flexible, but I would prefer an initial draft within a few days if possible.

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Additional Notes:
- Functionality and proper fitment are the top priorities
- Open to suggestions for improving strength, mounting, or appearance
- This is a practical automotive part, not just a visual model

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Please let me know if you need any additional information before starting.