"Every part was recreated using 3D printing. Denton used PLA filament and a belt-driven FDM printer, employing a 1 mm nozzle, two outer walls, and 10% infill to balance strength with manageability. Because of printing limitations, large plates and panels were split into smaller sections, so they would fit in the printer and to avoid warping. All curves and joints were first modeled precisely in CAD to ensure fit and performance under load."
"All curves and joints were first modeled precisely in CAD to ensure fit and performance under load. The final assembled buggy weighs about 102 kg - not light by any means, yet still light enough for hobby use. The build process reportedly took around 1,600 hours of printing and assembly, with numerous reprints required due to failed prints and printer issues."
A life-size version of the 1981 LEGO Technic 8845 Dune Buggy was scaled 10.42 times and rebuilt using 3D-printed components based on 50 mm axle bearings. The design was converted into a single-seat vehicle with a center-mounted steering wheel and a full-sized rack-and-pinion steering mechanism molded like an oversized LEGO piece. Parts were modeled in CAD and printed in PLA on a belt-driven FDM printer with a 1 mm nozzle, two outer walls, and 10% infill; large panels were split to avoid warping. An electric motor drives the rear axle via a belt-drive; the final assembled buggy weighs about 102 kg and required roughly 1,600 hours of printing and assembly.
Read at Yanko Design - Modern Industrial Design News
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