Any experience with 3D scan and 3D print for replicating plastic parts

[PT20J]

The best option for the GFC 500 yoke-mounted autopilot switches (trim and disconnect) seems to be to reuse the 25 year-old B-K cluster. However, I noticed a hairline crack in injection molded base piece. I think it can be repaired, but it occurred to me that this might be a good piece to replicate by 3D printing. However, the shape is a bit complex and I thought it might be easiest to 3D scan it to create a the model. I don't have any experience with 3D printing, but I know a number of you have done quite a bit of it. Any thoughts and/or recommendations of places that do this? If I got a 3D model, I could post it for others to use.

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[Bolter]

I used Xometry.com and was pleased with the parts, and customer support when there was shipping damage.  It was a completely automated process.  I uploaded the solid model (I use Solidworks) a price was calculated, and I clicked "buy".  This service is not unique, there are many competitors with probably equal performance.

DO anticipate the manufacturing needs.  Watch a few videos or read a blog.  My learning lesson was adding structure to support thin walls, that I removed later, or else they may sag under their own weight during the manufacturing process.  

I am out of PAE, if you want any assistance.  I can also help with making the solid model.  I do not have access to a 3D scanner, however.  

-dan

[Niko182]

Id personally do a cnc mold before a 3d print. It might be a bit more expensive, but it will lok considerable nicer with a smooth finish, than a 3d printed object. Just my 2 cents.

[AH-1 Cobra Pilot]

I do not have a scanner, but I do lots of printing.  If you can create a model, I would be happy to print it. 

Just make sure you use solids, not surfaces, when you create the model.

[FloridaMan]

Resin 3D printers are game changers are now less than $200. 
 

 

[bradp]

Another option is to reskin the original part in carbon. Or to make a plug and start fresh.  
 

I needed the same part but no BK autopilot housing to start from - so I made a plug from pink foam and skinned half of it in carbon.  Then I removed the first half from the plug, and skinned the second half to close it in.  Then micro and finish work.  Result was perfect for what I needed.  
 

 

[bradp]

This is a simple design that has the same function as the Bk and would be very straightforward to make. 

 

 

if you make a 3D printed part make sure to use ABS or the like - nothing else will stand up to the environmental stresses in the cockpit