Custom Car Plug Design

Hello,

I am requesting a **price estimate** for **3D printing a full-size automotive body plug**.
At this stage I am **only seeking pricing and feasibility**, not committing to production yet.

This part is a **tooling/master plug** that will be used to manufacture **fibreglass and carbon fibre composite moulds**.

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## PART PURPOSE (IMPORTANT)

* This is a **plug for mould making**, not a finished cosmetic body
* Strength and dimensional stability are the priority
* Surface finish will be completed post-print by myself
* **100% continuous outer skin required**
* **No doors, vents, apertures, or cut-outs**
* All openings will be cut **after moulding** to maintain plug strength

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## OVERALL SIZE (APPROXIMATE)

* Length: **~3900 mm**
* Width (body only): **~1750 mm**
* Height: **~1150 mm**
* Units: **millimetres**

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## PRINT STRATEGY

* Printing will be done in **multiple sections** to suit your maximum build volume
* Sections will be **bonded together** into one complete plug after printing
* Please advise recommended section sizes / split strategy for best cost and accuracy

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## STRUCTURAL REQUIREMENTS

* Continuous wall thickness: **4–5 mm**
* Infill: **10–15%**
* Top/bottom solid layers: **5 or more**
* Strength to be achieved via shell continuity (not sparse ribs)

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## MATERIAL

Please quote for the most suitable material for dimensional stability, for example:

* PLA+
* PETG
* ABS
(or your recommendation)

Heat resistance is not critical.

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## CAD FILES (PRICING STAGE)

For quotation purposes, I will upload a **simplified envelope CAD model** representing the full external volume of the plug.

* **STEP (.step)** – master CAD for pricing
* **STL (.stl)** – if required by your quoting system

This model is supplied **for cost and feasibility estimation only** and does not include final surface detailing, apertures, or trim lines.

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## WHAT I NEED FROM YOU

1. Estimated print cost (material and machine time)
2. Recommended material
3. Suggested sectioning strategy
4. Estimated lead time
5. Any file-preparation requirements before upload

This request is **for pricing only** at this stage.

Thank you for your time and I look forward to your response.

Kind regards,

Darren Tarmey
Car Body Concept
Mobile: 07908392758
Preston