The Art of Research: How We Design 3D-Printed Aftermarket Parts

At ScaleCraft Studios, designing high-quality 3D-printed aftermarket parts is more than just creating something that fits—it’s about historical accuracy, engineering precision, and adding a new level of realism to your scale models. But what exactly goes into the research process before a part even reaches the printer? Let’s take a deep dive into what it takes to bring these parts to life.

1. Identifying the Need

Before we start designing, we need to determine what modelers actually want and need. We analyze existing kits to identify areas that could use extra detail, improved accuracy, or alternative configurations, there are many kits from various brands that are underrepresented in terms of aftermarket/detail up parts. This involves:

• Reading modeler reviews and feedback on existing kits.
• Studying aftermarket gaps where no upgrade parts currently exist.
• Checking historical references to ensure the parts are accurate to the real aircraft or vehicle.

2. Gathering Reference Materials

To ensure our parts are historically and technically accurate, we gather as much reference material as possible. This includes:

• Technical Manuals & Blueprints: If available, original manufacturer blueprints and maintenance manuals provide invaluable technical specifications.
• Photographs: Archival and museum photos help capture fine details that might be missing from blueprints.
• Surviving Examples: Visiting museums or private collections allows us to inspect real-world examples and compare them to existing model kits. Though in reality this is hard to do. Acquiring permission to get access to these sometimes very rare machines can be impossible. Some surviving examples are in a poor condition or missing components. The only surviving Ho-229 is a good example, its both rare, hard to access and in a very poor condition.
• Expert Consultation: Engaging with historians, restoration experts, and seasoned modelers helps validate the accuracy of our research.

3. Digital Modelling & CAD Design

Once we have a clear understanding of the part we’re designing, we move into the digital modelling phase using CAD (Computer-Aided Design) software. This step involves:

• 3D Scanning (if possible): When available, scanning an original part helps create a highly accurate digital replica.
• Manual 3D Modelling: Using the collected references, we carefully recreate the part in CAD, ensuring proper dimensions and detailing.
• Fitment Considerations: Since our parts must integrate seamlessly with existing kits, we cross-reference measurements with the model kit components.

4. Prototyping & Testing

Once the digital model is complete, it’s time to print prototypes and test the parts for accuracy and usability. This involves:

• Test Printing: Using high-resolution resin 3D printers to produce the first physical samples.
• Dry Fitting: Testing the part against the model kit to ensure perfect fitment.
• Adjustments & Refinements: If needed, the model is tweaked for better fit, detail enhancement, or improved printability.

5. Finalizing for Production

After refining the prototype, we prepare the part for production by:

• Optimizing Print Orientation: Adjusting how the part prints to reduce supports and ensure the best surface detail.
• Resin Selection: Choosing the best resin type for durability and fine detail.
• Packaging & Instructions: Designing packaging and clear instructions to help modelers use the part effectively.

Conclusion

Creating high-quality 3D-printed aftermarket parts isn’t just about making something that looks good—it’s about precision, research, and a dedication to enhancing scale models in the most accurate way possible. At ScaleCraft Studios, we put in the work to ensure that every part we design meets the highest standards of detail and fitment. Whether it’s cockpit upgrades, engine components, or external details, our process guarantees that you’re getting aftermarket parts that truly bring your models to life.