The family owned and operated Emory Motorsports out of Oregon and California has Porsche restoration in its blood. For three generations and counting, the Emory family has restyled designs from the original “Baja Bug” to race-inspired street variants of the Porsche 911, earning the label “356 Outlaw” for their distinct restyling of the Porsche 356.

The spirit and mission of Emory Motorsports is to make old Porsches better than they ever were, both mechanically and aesthetically. The ultimate benchmark of this effort is the Emory Special, of which precious few have been made. Specials are one-off cars whose combination of design and mechanical components are unique to that specific model.



To stay up to speed with the technical precision of today’s manufacturing process, the creative team of Emory Motorsports decided to merge traditional fabrication techniques with the latest 3D tools, including Geomagic software and 3D printing by Quickparts. In January 2015, this strategic combination of scan/design technology and rapid prototyping came in handy when a customer asked for help in restyling the windshield frame for an early Porsche Roadster.



Although 3D CAD data for these sorts of vintage cars doesn’t exist, the team at Emory Motorsports was able to scan components directly into CAD using Geomagic Design X, and then design on top of them. Because Geomagic Design X combines history-based CAD with 3D scan data processing, Emory Motorsports could create feature-based, editable solid models compatible with the company’s existing CAD software.



Yet because computer simulations can only communicate so much, the Emory team wanted to check the size and fit of the on-screen part to the real-life car before committing to full production. To do this, they decided to 3D print a prototype with help from Quickparts, 3DS’ leading global on-demand 3D printing service. Within a five days, Emory Motorsports had their part.



With the customer on-site for the test-fit, Emory was able to achieve a closed-circuit validation for immediate feedback to keep the proverbial wheels in motion. “On a different kind of project, that print we got back could have even been used as a finished part,” said owner Rod Emory.



View the video of this project by Emory Motorsports here.