{"id":69045,"date":"2025-04-24T11:09:13","date_gmt":"2025-04-24T03:09:13","guid":{"rendered":"https:\/\/xometry.asia\/?p=69045"},"modified":"2025-05-19T15:35:22","modified_gmt":"2025-05-19T07:35:22","slug":"my-lotus-elan-se-journey-restoring-lotti-with-3d-printing","status":"publish","type":"post","link":"https:\/\/staging-wp.xometry.hk\/en\/my-lotus-elan-se-journey-restoring-lotti-with-3d-printing\/","title":{"rendered":"My Lotus Elan SE Journey: Restoring \u2018Lotti\u2019 with 3D Printing"},"content":{"rendered":"\n
Hi, my name is Chris, and this is the story of \u2018Lotti,\u2019 my 1991 Lotus Elan SE. My passion for Lotus cars began early, growing up near the factory in Norfolk, UK. An unforgettable open-day tour of the F1 team workshop, where I even got to sit in an era F1 car, sealed my lifelong admiration for Lotus. Forever Lotus!<\/p>\n\n\n\n
Chris Amos<\/h4>\n\n\n\n
Lotus enthusiast and Elan M100 owner<\/p>\n\n\n\n<\/figure>\n\n\n\n
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\n
The Challenge of Restoring Modern Classics<\/strong><\/h2>\n\n\n\n
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
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\n
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Original and damaged components from a 1991 Lotus Elan SE \u00a9Chris Amos<\/p>\n\n\n\n
Replacing the Door Seals with 3D Printing<\/strong><\/h2>\n\n\n\n
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
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\n
Improving the Original Design<\/strong><\/h2>\n\n\n\n
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
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\n
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\u00a9Chris Amos<\/p>\n\n\n\n
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The printed parts matched the design \u2013 and particularly the mounting holes on the door very precisely \u00a9Chris Amos<\/p>\n\n\n\n
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\u00a9Chris Amos<\/p>\n\n\n\n\n\n\n\n\n\n
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\n
Showcasing Innovation: 3D Printing at the NEC Classic Car Show<\/strong><\/h2>\n\n\n\n
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