{"id":64326,"date":"2024-11-27T09:12:41","date_gmt":"2024-11-27T08:12:41","guid":{"rendered":"https:\/\/xometry.pro\/stories\/lotus-elan-restoring-3d-printing\/"},"modified":"2024-11-27T10:21:04","modified_gmt":"2024-11-27T09:21:04","slug":"lotus-elan-restoring-3d-printing","status":"publish","type":"stories","link":"https:\/\/xometry.pro\/en\/stories\/lotus-elan-restoring-3d-printing\/","title":{"rendered":"My Lotus Elan SE Journey: Restoring \u2018Lotti\u2019 with 3D Printing"},"content":{"rendered":"<div role=\"navigation\" aria-label=\"Table of Contents\" class=\"simpletoc wp-block-simpletoc-toc\"><h2 class=\"simpletoc-title\">Table of Contents<\/h2>\n<ul class=\"simpletoc-list\">\n<li><a href=\"#h-the-challenge-of-restoring-modern-classics\">The Challenge of Restoring Modern Classics<\/a>\n\n<\/li>\n<li><a href=\"#replacing-the-door-seals-with-3d-printing\">Replacing the Door Seals with 3D Printing<\/a>\n\n<\/li>\n<li><a href=\"#h-improving-the-original-design\">Improving the Original Design<\/a>\n\n<\/li>\n<li><a href=\"#showcasing-innovation-3d-printing-at-the-nec-classic-car-show\">Showcasing Innovation: 3D Printing at the NEC Classic Car Show<\/a>\n<\/li><\/ul><\/div>\n\n\n<p>When I first saw Elan SEs driving around Norfolk, I promised myself, \u201cOne day I\u2019ll have one.\u201d Decades later, I made that dream a reality. Lotti has been with us for eight years now, bringing both joy and challenges.<\/p>\n\n\n<h2 class=\"wp-block-heading\" id=\"h-the-challenge-of-restoring-modern-classics\"><strong>The Challenge of Restoring Modern Classics<\/strong><\/h2>\n\n\n<p>Owning a modern classic like the Elan SE comes with its share of hurdles, especially when it comes to sourcing parts. While many components were mass-produced and remain accessible, a significant number of model-specific parts have become scarce\u2014or are no longer available.<\/p>\n\n\n\n<p>A prime example is the door, window, and soft-top seals. While some have been reproduced in small batches by specialists, most are out of production. The original fittings were not particularly effective, and the manufacturing processes used for them are now obsolete. 3D printing to the rescue!<\/p>\n\n\n    <section class=\"article-slider-block\">\r\n        <div class=\"article-content-wrapper\">\r\n            <!-- Swiper -->\r\n            <div class=\"swiper mySwiper2 article-slider-display\">\r\n                <div class=\"swiper-wrapper\">\r\n                                                <div class=\"swiper-slide\">\r\n                                <div class=\"wp-block-image__wrap\">\r\n                                    <img decoding=\"async\"  src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/original-damaged-lotus-elan-se-2-scaled.jpeg\" alt=\"\"\r\n                                    >\r\n                                    <a class=\"wp-block-image__fancy-box-button\" href=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/original-damaged-lotus-elan-se-2-scaled.jpeg\" data-fancybox=\"gallery\" data-caption=\"Original and damaged components from a 1991 Lotus Elan SE \u00a9Chris Amos\" aria-label=\"Open full image\">\r\n                                        <img src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/original-damaged-lotus-elan-se-2-scaled.jpeg\" class=\"wp-block-image__fancy-box-button-thumbnail wp-post-image\" alt=\"\" loading=\"lazy\" decoding=\"async\">\r\n                                        <svg class=\"wp-block-image__fancy-box-button-icon\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"18\" height=\"18\" viewBox=\"0 0 18 18\" fill=\"none\" aria-hidden=\"true\">\r\n                                            <path d=\"M0 2V6H2V2H6V0H2C0.895 0 0 0.895 0 2ZM2 12H0V16C0 17.105 0.895 18 2 18H6V16H2V12ZM16 16H12V18H16C17.105 18 18 17.105 18 16V12H16V16ZM16 0H12V2H16V6H18V2C18 0.895 17.105 0 16 0Z\" fill=\"#092C47\"><\/path>\r\n                                        <\/svg>\r\n                                    <\/a>\r\n                                <\/div>\r\n                                <div class=\"article-slider-text\">\r\n                                    <p>Original and damaged components from a 1991 Lotus Elan SE \u00a9Chris Amos<\/p>\n                                <\/div>\r\n                            <\/div>\r\n                            \r\n                                                        <div class=\"swiper-slide\">\r\n                                <div class=\"wp-block-image__wrap\">\r\n                                    <img decoding=\"async\"  src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/original-damaged-lotus-elan-se-scaled.jpeg\" alt=\"\"\r\n                                    >\r\n                                    <a class=\"wp-block-image__fancy-box-button\" href=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/original-damaged-lotus-elan-se-scaled.jpeg\" data-fancybox=\"gallery\" data-caption=\"\u00a9Chris Amos\" aria-label=\"Open full image\">\r\n                                        <img src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/original-damaged-lotus-elan-se-scaled.jpeg\" class=\"wp-block-image__fancy-box-button-thumbnail wp-post-image\" alt=\"\" loading=\"lazy\" decoding=\"async\">\r\n                                        <svg class=\"wp-block-image__fancy-box-button-icon\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"18\" height=\"18\" viewBox=\"0 0 18 18\" fill=\"none\" aria-hidden=\"true\">\r\n                                            <path d=\"M0 2V6H2V2H6V0H2C0.895 0 0 0.895 0 2ZM2 12H0V16C0 17.105 0.895 18 2 18H6V16H2V12ZM16 16H12V18H16C17.105 18 18 17.105 18 16V12H16V16ZM16 0H12V2H16V6H18V2C18 0.895 17.105 0 16 0Z\" fill=\"#092C47\"><\/path>\r\n                                        <\/svg>\r\n                                    <\/a>\r\n                                <\/div>\r\n                                <div class=\"article-slider-text\">\r\n                                    <p>\u00a9Chris Amos<\/p>\n                                <\/div>\r\n                            <\/div>\r\n                            \r\n                                            <\/div>\r\n            <\/div>\r\n            <div thumbsSlider=\"\" class=\"swiper mySwiper article-slider-list\">\r\n                <div class=\"swiper-wrapper\">\r\n                                            <div class=\"swiper-slide\">\r\n                            <img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/original-damaged-lotus-elan-se-2-scaled.jpeg\" alt=\"\">\r\n                        <\/div>\r\n                                                <div class=\"swiper-slide\">\r\n                            <img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/original-damaged-lotus-elan-se-scaled.jpeg\" alt=\"\">\r\n                        <\/div>\r\n                                        <\/div>\r\n            <\/div>\r\n        <\/div>\r\n    <\/section>\r\n    \n\n<h2 class=\"wp-block-heading\" id=\"replacing-the-door-seals-with-3d-printing\"><strong>Replacing the Door Seals with 3D Printing<\/strong><\/h2>\n\n\n<p>On Lotti, the passenger-side door seal was still intact, featuring a sponge-like core with a plastic outer coating. However, the driver-side seal had completely disintegrated. A fellow enthusiast helped source custom seals for the door, but certain areas\u2014particularly the top and rear\u2014still needed attention. I saw potential in using TPU (thermoplastic polyurethane) for this project.<\/p>\n\n\n\n<p>In the absence of drawings, the workflow I adopted was to design replacement parts from scratch and print them at home using TPU materials. Once the design was finalized, I turned to Xometry for more advanced manufacturing services to produce precise, durable seals with a superior finish.<\/p>\n\n\n<h2 class=\"wp-block-heading\" id=\"h-improving-the-original-design\"><strong>Improving the Original Design<\/strong><\/h2>\n\n\n<p>Interestingly, the original seal design didn\u2019t fully serve its purpose. My new design avoids these shortcomings while allowing for customization. I divided the seal into three parts to accommodate the constraints of home 3D printing. This modular approach also benefits other Elan owners, as each car varies slightly, and the parts can be tailored without a complete redesign.<\/p>\n\n\n\n<p>The parts pictured below demonstrate the fit with the window trim and rear door trim. Xometry produced these components using TPU and the Selective Laser Sintering (SLS) process. I plan to test additional iterations and produce parts using Xometry\u2019s HP Multi Jet Fusion (MJF) process for an even better finish. I\u2019m aiming for something that matches the finish on the original seals as far as possible with sufficient flexibility to make a weatherproof fit. There are also some other elements of the seals that are wearing so the next step will be to consider how best to replace those.<\/p>\n\n\n    <section class=\"article-slider-block\">\r\n        <div class=\"article-content-wrapper\">\r\n            <!-- Swiper -->\r\n            <div class=\"swiper mySwiper2 article-slider-display\">\r\n                <div class=\"swiper-wrapper\">\r\n                                                <div class=\"swiper-slide\">\r\n                                <div class=\"wp-block-image__wrap\">\r\n                                    <img decoding=\"async\"  src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/tpu-parts-lotus-elan-scaled.jpeg\" alt=\"TPU 3D printed replacements\"\r\n                                    >\r\n                                    <a class=\"wp-block-image__fancy-box-button\" href=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/tpu-parts-lotus-elan-scaled.jpeg\" data-fancybox=\"gallery\" data-caption=\"\u00a9Chris Amos\" aria-label=\"Open full image\">\r\n                                        <img src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/tpu-parts-lotus-elan-scaled.jpeg\" class=\"wp-block-image__fancy-box-button-thumbnail wp-post-image\" alt=\"TPU 3D printed replacements\" loading=\"lazy\" decoding=\"async\">\r\n                                        <svg class=\"wp-block-image__fancy-box-button-icon\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"18\" height=\"18\" viewBox=\"0 0 18 18\" fill=\"none\" aria-hidden=\"true\">\r\n                                            <path d=\"M0 2V6H2V2H6V0H2C0.895 0 0 0.895 0 2ZM2 12H0V16C0 17.105 0.895 18 2 18H6V16H2V12ZM16 16H12V18H16C17.105 18 18 17.105 18 16V12H16V16ZM16 0H12V2H16V6H18V2C18 0.895 17.105 0 16 0Z\" fill=\"#092C47\"><\/path>\r\n                                        <\/svg>\r\n                                    <\/a>\r\n                                <\/div>\r\n                                <div class=\"article-slider-text\">\r\n                                    <p>\u00a9Chris Amos<\/p>\n                                <\/div>\r\n                            <\/div>\r\n                            \r\n                                                        <div class=\"swiper-slide\">\r\n                                <div class=\"wp-block-image__wrap\">\r\n                                    <img decoding=\"async\"  src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/3d-printed-replacement-seals-lotus-elan-2-scaled.jpeg\" alt=\"\"\r\n                                    >\r\n                                    <a class=\"wp-block-image__fancy-box-button\" href=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/3d-printed-replacement-seals-lotus-elan-2-scaled.jpeg\" data-fancybox=\"gallery\" data-caption=\"The printed parts matched the design \u2013 and particularly the mounting holes on the door very precisely \u00a9Chris Amos\" aria-label=\"Open full image\">\r\n                                        <img src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/3d-printed-replacement-seals-lotus-elan-2-scaled.jpeg\" class=\"wp-block-image__fancy-box-button-thumbnail wp-post-image\" alt=\"\" loading=\"lazy\" decoding=\"async\">\r\n                                        <svg class=\"wp-block-image__fancy-box-button-icon\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"18\" height=\"18\" viewBox=\"0 0 18 18\" fill=\"none\" aria-hidden=\"true\">\r\n                                            <path d=\"M0 2V6H2V2H6V0H2C0.895 0 0 0.895 0 2ZM2 12H0V16C0 17.105 0.895 18 2 18H6V16H2V12ZM16 16H12V18H16C17.105 18 18 17.105 18 16V12H16V16ZM16 0H12V2H16V6H18V2C18 0.895 17.105 0 16 0Z\" fill=\"#092C47\"><\/path>\r\n                                        <\/svg>\r\n                                    <\/a>\r\n                                <\/div>\r\n                                <div class=\"article-slider-text\">\r\n                                    <p>The printed parts matched the design \u2013 and particularly the mounting holes on the door very precisely \u00a9Chris Amos<\/p>\n                                <\/div>\r\n                            <\/div>\r\n                            \r\n                                                        <div class=\"swiper-slide\">\r\n                                <div class=\"wp-block-image__wrap\">\r\n                                    <img decoding=\"async\"  src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/3d-printed-replacement-seals-lotus-elan-scaled.jpeg\" alt=\"\"\r\n                                    >\r\n                                    <a class=\"wp-block-image__fancy-box-button\" href=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/3d-printed-replacement-seals-lotus-elan-scaled.jpeg\" data-fancybox=\"gallery\" data-caption=\"\u00a9Chris Amos\" aria-label=\"Open full image\">\r\n                                        <img src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/3d-printed-replacement-seals-lotus-elan-scaled.jpeg\" class=\"wp-block-image__fancy-box-button-thumbnail wp-post-image\" alt=\"\" loading=\"lazy\" decoding=\"async\">\r\n                                        <svg class=\"wp-block-image__fancy-box-button-icon\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"18\" height=\"18\" viewBox=\"0 0 18 18\" fill=\"none\" aria-hidden=\"true\">\r\n                                            <path d=\"M0 2V6H2V2H6V0H2C0.895 0 0 0.895 0 2ZM2 12H0V16C0 17.105 0.895 18 2 18H6V16H2V12ZM16 16H12V18H16C17.105 18 18 17.105 18 16V12H16V16ZM16 0H12V2H16V6H18V2C18 0.895 17.105 0 16 0Z\" fill=\"#092C47\"><\/path>\r\n                                        <\/svg>\r\n                                    <\/a>\r\n                                <\/div>\r\n                                <div class=\"article-slider-text\">\r\n                                    <p>\u00a9Chris Amos<\/p>\n                                <\/div>\r\n                            <\/div>\r\n                            \r\n                                            <\/div>\r\n            <\/div>\r\n            <div thumbsSlider=\"\" class=\"swiper mySwiper article-slider-list\">\r\n                <div class=\"swiper-wrapper\">\r\n                                            <div class=\"swiper-slide\">\r\n                            <img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/tpu-parts-lotus-elan-scaled.jpeg\" alt=\"TPU 3D printed replacements\">\r\n                        <\/div>\r\n                                                <div class=\"swiper-slide\">\r\n                            <img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/3d-printed-replacement-seals-lotus-elan-2-scaled.jpeg\" alt=\"\">\r\n                        <\/div>\r\n                                                <div class=\"swiper-slide\">\r\n                            <img decoding=\"async\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/3d-printed-replacement-seals-lotus-elan-scaled.jpeg\" alt=\"\">\r\n                        <\/div>\r\n                                        <\/div>\r\n            <\/div>\r\n        <\/div>\r\n    <\/section>\r\n    \n\n\n<p>The modular parts\u2014designed for easy assembly\u2014precisely match the Elan\u2019s mounting holes. One part bolts to the end of the door, another interfaces with the outer door seal, and the third covers the inner door card cutout.<\/p>\n\n\n<h2 class=\"wp-block-heading\" id=\"showcasing-innovation-3d-printing-at-the-nec-classic-car-show\"><strong>Showcasing Innovation: 3D Printing at the NEC Classic Car Show<\/strong><\/h2>\n\n\n<p>The Elan with prototype parts was exhibited on the Lotus Drivers Club stand at the <a href=\"https:\/\/www.necclassicmotorshow.com\/\" target=\"_blank\" rel=\"noreferrer noopener\">Classic Car exhibition at the NEC<\/a>, Birmingham in November 2024. The 3d printing for parts generated a great deal of attention\u2014and it was interesting to hear some comments from those in the auto industry about how it was used in mainstream manufacturing.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><div class=\"wp-block-image__wrap\"><img decoding=\"async\" width=\"1024\" height=\"683\" src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/lotus-classic-car-exhibition-nec-1024x683.png\" alt=\"The 1991 Lotus Elan SE at the Classic Car exhibition at the NEC\" class=\"wp-image-63687\" srcset=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/lotus-classic-car-exhibition-nec-1024x683.png 1024w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/lotus-classic-car-exhibition-nec-300x200.png 300w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/lotus-classic-car-exhibition-nec-768x512.png 768w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/lotus-classic-car-exhibition-nec-1536x1024.png 1536w, https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/lotus-classic-car-exhibition-nec.png 2048w\" sizes=\"(max-width: 1024px) 100vw, 1024px\" \/><a class=\"wp-block-image__fancy-box-button\" href=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/lotus-classic-car-exhibition-nec.png\" data-fancybox=\"gallery-64326\" data-caption=\"The 1991 Lotus Elan SE at the Classic Car exhibition at the NEC \u00a9Chris Tresadern-Jones\" aria-label=\"Open full image\"><img src=\"https:\/\/xometry.pro\/wp-content\/uploads\/2024\/11\/lotus-classic-car-exhibition-nec.png\" class=\"wp-block-image__fancy-box-button-thumbnail wp-post-image\" alt=\"\" loading=\"lazy\" decoding=\"async\"><svg class=\"wp-block-image__fancy-box-button-icon\" xmlns=\"http:\/\/www.w3.org\/2000\/svg\" width=\"18\" height=\"18\" viewBox=\"0 0 18 18\" fill=\"none\" aria-hidden=\"true\">\r\n               <path d=\"M0 2V6H2V2H6V0H2C0.895 0 0 0.895 0 2ZM2 12H0V16C0 17.105 0.895 18 2 18H6V16H2V12ZM16 16H12V18H16C17.105 18 18 17.105 18 16V12H16V16ZM16 0H12V2H16V6H18V2C18 0.895 17.105 0 16 0Z\" fill=\"#092C47\"\/>\r\n             <\/svg><\/a><\/div><figcaption class=\"wp-element-caption\">The 1991 Lotus Elan SE at the Classic Car exhibition at the NEC \u00a9Chris Tresadern-Jones<\/figcaption><\/figure>\n\n\n\n<p><strong>Learn more about the Lotus Drivers Club:<\/strong> <a href=\"https:\/\/www.lotusdriversclub.org.uk\/\" target=\"_blank\" rel=\"noreferrer noopener\">https:\/\/www.lotusdriversclub.org.uk\/<\/a> and <a href=\"https:\/\/www.facebook.com\/groups\/18414574095\" target=\"_blank\" rel=\"noreferrer noopener\">https:\/\/www.facebook.com\/groups\/18414574095<\/a> <\/p>\n\n\n\n<hr class=\"wp-block-separator has-text-color has-alpha-channel-opacity has-background\" style=\"background-color:#f5f7f8;color:#f5f7f8\"\/>\n\n\n\n<p><strong>Have you used 3D printing for restoring classic cars or solving unique challenges?<\/strong> Share your experiences, ideas, or questions about innovative restoration methods!&nbsp;<\/p>\n\n\n\n<p><\/p>\n","protected":false},"author":50,"featured_media":63701,"comment_status":"open","ping_status":"closed","template":"","c-tag-stories":[298,301],"global-tag":[12],"class_list":["post-64326","stories","type-stories","status-publish","has-post-thumbnail","hentry","c-tag-stories-automotive","c-tag-stories-hobby","global-tag-3d-printing"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO Premium plugin v26.7 (Yoast SEO v27.3) - https:\/\/yoast.com\/product\/yoast-seo-premium-wordpress\/ -->\n<title>My Lotus Elan SE Journey: Restoring \u2018Lotti\u2019 with 3D Printing | Xometry Pro<\/title>\n<meta name=\"description\" content=\"Hi, my name is Chris, and this is the story of \u2018Lotti,\u2019 my 1991 Lotus Elan SE and how I restored it with the help of 3D printing.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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