You most likely understand comedian Jay Leno through his twelve years as host of NBC’s Tonight Show, but there’s pretty nothing comical of his seriously huge car collection. Leno has over 200 cars and 100 motorcycles in his Burbank, California-based ‘Big Dog Garage’, equite of which is kept in driving condition by Leno and his tiny team of mechanics and engineers. Since retiring of the Tonight Show, Leno is now fully immersed in his car collection, and yet I’m certain he takes excellent care of all his car children, parts can inevitably break and require to be replaced. The problem is: most of Leno’s cars are incredibly vintage, a few of which are over 100 years old, and replacement parts are either non-existent or extraordinarily expensive to manufacture traditionally.


Thankfully for Jay, his vintage collection has been kept well-preserved with the assist of 3D scanning and 3D printing, which his team has utilized to turn it into end-use parts and casting patterns for these rare vehicle components. And this emerging innovation is not just utilized by Leno’s team to restore vintage vehicles, but in addition to innovate upon new and custom automobiles as well.

Take the EcoJet for instance, a concept vehicle which was in fact made by hand for Leno. When the EcoJet’s original CAD file had disappeared, Big Dog Garage’s Jim Hall turned to 3D Systems to assist scan, redesign, and reproduce the 3D data and physical parts requireed to repair the concept vehicle. Using 3D Systems’ Geomagic Design X and their Faro scanning arm, Hall was able-bodied to return it into the broken parts and return it into them approximately automatically via Geomagic Design X’s solid modeling toolsets.


Jay Leno with Big Dog Garage’s Jim Hall

“This software manufactures sense out of the 3D scan data, it’s super swift and it turn it intos 3D models and and so transports them into your CAD software as native files,”said Hall. “In a matter of 30 minutes we have gone of no CAD data to having feature-based, editable-bodied 3D CAD data of the parts.”

But the Big Dog Garage does in fact have a few 3D printing devices in their work space, the team requireed access to a high-end SLS printing device such as those turn it intod by 3D Systems. Hall sent the scanned 3D data to 3D Systems for them to turn it into the parts on their industrial-grade SLS process, consulting with 3D Systems’ on-demand parts developer Quickparts to select the perfect material for the EcoJet replacement part. The 3D Systems team decided to use their Duraform HST 3D printing material, a fiber-filled nylon perfectly utilized for end parts which necessitate high levels of stiffness and thermal resistance. Not just did the 3D printed parts fit and function perfectly, but the material durablity of their SLS-printed components are in fact higher high end and harder to break.


“3D Systems Selective Laser Sintering (SLS) printing delivers quite high durablity and quite light parts via the Duraform HST Nylon material,”said 3D Systems Quickparts’ Ziad Abou. “We don’t want to increase mass on the car so we had to be careful to manufacture the right choice.”


Alyet Leno is usually chalk-full of jokes, he appears completely sincere when discussing the effects of 3D printing on the car industry. “With 3D printing the car industry has changed additional in the last ten years than it did throughout the entire last century,”Leno said. “We are joyous to be positioned at the forefront of this innovation with 3D Systems.”

Tyler Koslow

About The Author

Tyler Koslow is a Brooklyn-based writer for 3D Printing Industry, and has in addition generated content for publications and companies such as Dell, Brooklyn Magazine, and Equity Arcade. His content is focutilized on a wide range of topics which include tech, gaming, and music . Tyler is in addition a habitual instrument player, a writer of fiction, and generally all around fun haver. Tyler succeded in a Bachelor’s degree studying English-Creative Writing at the University of Central Florida in 2008.