Development Process

  1. 3D Scanning: Our skilled technicians employ state-of-the-art 3D scanning technology to capture precise digital models of original Corvette parts from the C1, C2, and C3 series. These scanners use lasers or structured light to create detailed, high-resolution point clouds, capturing every contour and intricate detail of the components.

  2. Digital Modeling: The 3D point cloud data is processed and converted into a digital 3D model using sophisticated software. This digital model serves as a virtual blueprint, preserving the exact dimensions and design of the original parts.

  3. Quality Verification: To ensure accuracy and fidelity to the original parts, the digital models are meticulously cross-referenced with physical measurements from the actual components.

  4. 3D Printing: Once the digital models are verified and approved, they are sent to our advanced 3D printers. We utilize cutting-edge additive manufacturing technologies, which can produce high-quality, durable, replicas that we can then model molds around for our other processes.

  5. Fabrication: Sometimes our molds or products require custom fabrication. Our shop is equipped with a wide variety metals equipment including welding, Plasma cutting, and powdercoating. All to help in our development of new and reproduction of old Corvette components. 
Advantages of 3D Scanning and 3D Printing for Classic Corvette Reproductions:

  1. Preserving Heritage: Our 3D scanning and printing technology allow us to faithfully recreate classic Corvette parts, ensuring their legacy lives on and that future generations can continue to enjoy these timeless vehicles.

  2. High Accuracy: 3D scanning captures even the most intricate details, guaranteeing that the reproductions are exact replicas of the original components.

  3. Customizability: If desired, minor modifications or enhancements can be made to the digital models to accommodate modern improvements while still preserving the classic aesthetics.

  4. Rarity and Availability: As many original Corvette parts become increasingly rare and hard to find, 3D scanning and printing offer a viable solution to reproduce discontinued components that are no longer in production.

  5. Time and Cost Efficiency: With traditional manufacturing methods, producing limited runs of classic car parts can be cost-prohibitive and time-consuming. 3D scanning and printing streamline the process, reducing both lead times and costs.

Whether you're restoring a classic Corvette or wanting something custom, our 3D scanning and printing services are dedicated to providing you with faithful reproductions that match the charm and authenticity of the original components.

About Our Fiberglass Process

Our hand-laid fiberglass parts crafted with vinyl ester resin are the epitome of excellence and durability. Combining meticulous craftsmanship with high-performance materials, these parts are designed to meet the highest standards of quality and performance.

Each hand-laid fiberglass part is created with utmost precision, where layers of fiberglass matting or sheets are carefully placed and saturated with vinyl ester resin. This manual process allows for complete control over the fiber orientation, resin saturation, and overall construction, resulting in a finished product that boasts exceptional strength and structural integrity.

The use of vinyl ester resin takes these hand-laid fiberglass parts to the next level. Vinyl ester resin is renowned for its superior chemical resistance, making it the ideal choice for applications that require protection against corrosive substances and harsh environments. Its resistance to a wide range of chemicals ensures that these parts remain intact and unaffected even under the most demanding conditions.

In addition to its exceptional chemical resistance, vinyl ester resin also offers outstanding strength and durability. These hand-laid fiberglass parts exhibit enhanced mechanical properties, including impressive tensile strength, flexural strength, and impact resistance. This makes them well-suited for applications that require robust and long-lasting components, ensuring they can withstand the rigors of daily use.

Furthermore, vinyl ester resin provides excellent resistance to moisture and UV exposure. Moisture absorption is minimized, reducing the risk of delamination or degradation over time. Additionally, the superior UV resistance of vinyl ester resin protects these parts from the damaging effects of prolonged sun exposure, such as fading, discoloration, or surface degradation.

The hand-laid fiberglass parts with vinyl ester resin also offer exceptional dimensional stability. Thanks to the minimal shrinkage characteristics of vinyl ester resin during the curing process, these parts maintain their shape and integrity, ensuring a precise fit and reducing the risk of warping or distortion.

Hand-Laid Vs Chopper Gun

When it comes to the construction of fiberglass parts, hand-laid fiberglass and chopper gun are two commonly used techniques. While both methods have their merits, there are several reasons why hand-laid fiberglass stands out as the superior choice.

  1. Quality and Strength: Hand-laid fiberglass involves meticulously layering fiberglass sheets or matting, impregnated with resin, by hand. This manual process allows for greater control over the fiber orientation and resin saturation, resulting in a stronger and more durable finished product. The individual attention to detail ensures consistent thickness and strength throughout the fiberglass part, reducing the risk of weak spots or uneven areas.

  2. Flexibility and Customization: Hand-laid fiberglass offers greater flexibility and customization options. The manual process allows for intricate detailing and shaping, making it ideal for producing complex or custom-designed parts. Skilled craftsmen can easily adjust the layers, add reinforcements, or modify the layup process to meet specific requirements, resulting in a tailored and precise end product.

  3. Weight Control: Hand-laid fiberglass allows for precise control over the weight of the final part. By adjusting the number of fiberglass layers or utilizing lightweight materials, such as carbon fiber or Kevlar, the weight can be optimized without compromising strength. This flexibility is particularly advantageous in industries where weight reduction is crucial for performance, such as automotive or aerospace.

  4. Surface Finish: Hand-laid fiberglass generally produces a superior surface finish compared to chopper gun. The manual application allows for better resin distribution and minimizes the occurrence of air pockets or voids, resulting in a smoother and more refined surface. This advantage is especially important for applications where aesthetics or paint quality are critical, such as show cars or high-end architectural elements.

  5. Structural Integrity: Hand-laid fiberglass offers superior structural integrity due to the meticulous layering and resin saturation. This technique ensures proper bonding between layers, resulting in a monolithic structure with exceptional strength. In contrast, chopper gun, which utilizes a spray-on method, may lead to inconsistent resin distribution and bonding, potentially compromising the overall structural integrity of the part.

  6. Environmental Considerations: Hand-laid fiberglass tends to be more environmentally friendly compared to chopper gun. The manual process allows for better control over the amount of resin used, reducing waste and minimizing the release of harmful emissions. Additionally, hand-laid fiberglass allows for easier recycling or repair of damaged parts, contributing to a more sustainable approach.

While chopper gun can offer advantages in terms of speed and cost-effectiveness for large-scale production, hand-laid fiberglass excels in terms of quality, strength, customization, and overall performance. Its attention to detail, superior surface finish, and structural integrity make it the preferred choice for applications where precision, durability, and aesthetics are paramount.

Vinyl Ester Resin Vs General Purpose Resin

When it comes to selecting a resin for fiberglass applications, vinyl ester resin offers several advantages over general-purpose resin. Here's a comparison highlighting why vinyl ester resin is considered superior in many cases:

  1. Chemical Resistance: Vinyl ester resin demonstrates excellent resistance to a wide range of chemicals, including acids, alkalis, and solvents. This makes it highly suitable for applications where the fiberglass part will come into contact with corrosive substances or environments. In contrast, general-purpose resin may be more susceptible to chemical degradation, leading to reduced durability and potential failure.

  2. Superior Strength and Durability: Vinyl ester resin offers superior mechanical properties compared to general-purpose resin. It provides enhanced tensile strength, flexural strength, and impact resistance, making it ideal for demanding applications that require high-performance and long-lasting fiberglass parts. The improved strength and durability of vinyl ester resin result in a more reliable and robust end product.

  3. Resistance to Moisture and UV Exposure: Vinyl ester resin exhibits excellent resistance to moisture absorption, which helps prevent delamination and degradation over time. It is also highly resistant to ultraviolet (UV) radiation, offering superior protection against UV-induced degradation, discoloration, and surface degradation. General-purpose resin may be more prone to moisture absorption and UV damage, potentially compromising the structural integrity and appearance of the fiberglass part.

  4. Reduced Shrinkage and Distortion: Vinyl ester resin experiences minimal shrinkage during the curing process, resulting in reduced warping or distortion of the fiberglass part. This characteristic is especially important when producing large or complex structures that require dimensional stability. In contrast, general-purpose resin may exhibit greater shrinkage, leading to potential quality issues and dimensional inaccuracies.

  5. Enhanced Fire Resistance: Vinyl ester resin possesses superior fire resistance properties compared to general-purpose resin. It exhibits higher flame-retardant capabilities and lower smoke emission, making it suitable for applications where fire safety is a concern. This advantage makes vinyl ester resin a preferred choice in industries such as aerospace, marine, and construction, where fire resistance is a critical requirement.

  6. Application Specificity: Vinyl ester resin is specifically formulated for high-performance and specialized applications. It is commonly used in industries such as automotive, aerospace, marine, and chemical processing, where stringent performance and durability requirements must be met. General-purpose resin, on the other hand, is more versatile but may not offer the same level of performance or suitability for demanding applications.

While general-purpose resin can be more cost-effective and suitable for certain non-critical applications, vinyl ester resin provides enhanced chemical resistance, superior strength and durability, resistance to moisture and UV exposure, reduced shrinkage, and improved fire resistance. These qualities make vinyl ester resin the preferred choice when it comes to producing high-performance fiberglass parts that need to withstand challenging environments and demanding conditions.

About Our Carbon Fiber Process

  1. Material Selection: Carbon fiber is a composite material made of extremely thin fibers primarily composed of carbon atoms. These fibers are combined with an epoxy resin, forming a strong and lightweight composite.

  2. Preparation of Carbon Fiber Fabric: The carbon fiber fabric used in the panel is either in the form of "prepreg" (already impregnated with resin) or dry fabric that will be infused with resin during the manufacturing process.

  3. Layering and Resin Infusion: The carbon fiber fabric is cut into the desired shape and layered in a mold. Epoxy resin is then applied to each layer of fabric, ensuring thorough impregnation and uniform distribution of the resin.

  4. Vacuum Bagging and Curing: The mold with the carbon fiber layup is placed inside a vacuum bag, and the air is removed using a vacuum pump. This process compacts the layers and eliminates air bubbles, resulting in a stronger and more uniform panel. The assembly is then cured in an oven or autoclave, depending on the resin system, to achieve its maximum strength.

  5. Trimming and Finishing: After curing, excess material is trimmed, and any finishing touches, such as sanding and polishing, are applied to achieve a smooth and visually appealing surface.

Advantages of Carbon Fiber Body Panels over Fiberglass:

  1. Weight: Carbon fiber is exceptionally lightweight, making it ideal for body panels. It is about 40-50% lighter than fiberglass, reducing the overall weight of the vehicle or aircraft and improving its performance, agility, and fuel efficiency.

  2. Strength and Rigidity: Carbon fiber panels offer exceptional strength-to-weight ratios, making them incredibly strong and rigid. They can withstand high stresses, impacts, and loads, providing enhanced safety and structural integrity.

  3. Fatigue Resistance: Carbon fiber exhibits excellent fatigue resistance, which means it can endure repetitive loads and vibrations over time without losing its structural properties. In contrast, fiberglass can experience fatigue and weaken under prolonged stress.

  4. Styling Flexibility: Carbon fiber's superior molding capabilities allow for complex and aerodynamic designs, providing more creative freedom in creating visually appealing and functional body panels.

  5. Corrosion Resistance: Carbon fiber is inherently corrosion-resistant, unlike fiberglass, which may corrode over time in certain environments.

  6. Thermal Conductivity: Carbon fiber dissipates heat more efficiently than fiberglass, making it suitable for applications where temperature management is crucial.

  7. High-Performance Applications: Due to its exceptional properties, carbon fiber is commonly used in high-performance vehicles, aircraft, and sporting equipment, where lightweight and strength are paramount.

In summary, carbon fiber body panels are manufactured using advanced techniques to harness the unique properties of this material. They are significantly lighter, stronger, and more durable than their fiberglass counterparts. These attributes not only improve the overall performance of the vehicle but also enhance its safety and longevity. If you're looking for a premium and high-performance solution, carbon fiber body panels are undoubtedly the superior choice.