Prototal partnered with Retropower, a specialist in high-end classic car restorations, to manufacture large, high-quality polymer components that exceeded the limits of the customer’s in-house 3D printing capabilities. Using industrial 3D printing, combined with dyeing and vapor smoothing, Prototal delivered dimensionally accurate parts with premium surface finish — supporting both functional performance and authentic aesthetics.
Retropower is a UK-based automotive specialist known for precision-engineered restorations of classic and performance vehicles. Their projects demand components that meet strict requirements for fit, finish, and visual authenticity, often at sizes and quality levels that exceed desktop or small-format additive manufacturing systems.
Customer Challenge
Retropower initially approached Prototal’s site in the UK to overcome limitations in their internal production setup.
Key challenges included:
- Build volume constraints, preventing large components from being produced in one piece
- Inconsistent quality and surface finish from carbon-filled nylon parts
- Limited process transparency and technical support from previous suppliers
- Difficulty achieving tight tolerances for functional and customer-facing components
These challenges restricted Retropower’s ability to produce parts that matched the quality of their vehicle builds.
Manufacturing Approach
Prototal addressed Retropower’s priorities of finish, quality, and build size using an industrial 3D printing workflow.
Technology and Material Selection
- Selective Laser Sintering (SLS)
- PA 603-CF (Nylon 12), selected for strength, dimensional stability, and consistency
- Post-processing: black dyeing and vapor smoothing for improved surface quality
Although Retropower had prior experience with PA 603-CF, Prototal’s industrial-scale SLS systems enabled significantly higher consistency, accuracy, and part size.
Produced Components
Prototal UK manufactured several key parts for Retropower’s restoration projects, including:
- Audi Quattro front grille assemblies
Manufactured as single-piece components using large-format SLS, eliminating assembly lines and improving structural integrity. - Jensen Interceptor intake pipes
Produced with a consistent 3 mm wall thickness and high dimensional accuracy, resulting in a precise fit for a complex duct design. - Austin Allegro demister duct components
Reproduced with a surface texture closely matching the original 1990s finish, meeting both functional and aesthetic requirements.
Collaboration and Technical Support
In addition to part production, Prototal supported Retropower through a collaborative and transparent working process:
- Clear communication throughout design and production
- Practical technical guidance on materials and design choices
- Access to the wider Prototal Group manufacturing network, enabling alternative technologies or materials to be sourced across Europe when required
This ensured continuity, flexibility, and access to the most suitable manufacturing solution for each application.
Results
The collaboration resolved both the quality and scale challenges Retropower faced.
Key outcomes included:
- Large-format components produced to specification in single pieces
- Improved surface finish and visual consistency through vapor smoothing
- Reliable dimensional accuracy on functional parts
- Textured components matching original vehicle designs
- A transparent and predictable manufacturing process
Beyond the immediate project requirements, Retropower now has access to a broader range of Industrial 3D Printing and traditional manufacturing capabilities across the Prototal Group, including metal production via CA Models for future applications.
This case demonstrates how industrial 3D Printing and controlled post-processing can support high-end restoration projects that require both technical precision and visual authenticity. By combining scalable production capacity with close technical collaboration, Prototal enabled Retropower to achieve consistent quality at a level aligned with premium automotive restoration standards.
