Mike Lake has 3D printed the entire body of his dream car, a Porsche 992 GT3 RS, for real-world use. For the chassis and engine, Lake turned to a donor Porsche Boxster 986, which means all he needed to do, in theory, was make some adjustments and fit the printed bodywork to the Boxster’s chassis.
However, it wasn’t that simple. The job involved intricacies down to the level of each millimeter, as Lake had to get each panel printed to match the original specification and ensure it was compatible with the Boxster chassis that was available to him.
What is surprising is that Lake reportedly used regular consumer 3D printers for the job, printing each panel in sections using PETG, and then assembling, reinforcing, and shaping them to match the Porsche GT3 RS’s original design.
One needs to be very patient with such jobs, as the components took over 2,000 hours to print, using 60 rolls of filament, with the entire car assembled like puzzle pieces.
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Then, the panels had to be bonded together in a way that replicates the real 992 GT3 RS, using fiberglass, filler, and custom supports so that the components hold up even at triple-digit speeds.
Lake intends to make his dream car as functional as possible and has gone to great lengths to adapt the Boxster’s mechanicals to fit the 992 GT3 RS body. Not only that, but he also added a turbo to the rear-mounted engine, which means he is being serious about the car’s performance.
Speaking of performance, Lake ensured he got the aerodynamics right with an active DRS rear wing for drag reduction, meaning his 3D-printed 992 GT3 RS may be able to reach speeds of over 150 mph with a light and aerodynamic body. We’re sure that he’s worked out how the panels hold together at those speeds.
The 3D-printed 992 GT3 RS is a work-in-progress project according to Lake’s recent posts on Instagram, but it won’t be too long before the car is ready. Lake said to one of the users in the comments section that the entire build cost of the car, including wheels, coilovers, etc., was around AUD 30,000.
