TL;DR- I've come to an impasse in my additive manufacturing of parts. Currently, I have my front grille 3D scanned (not perfect, but good enough) yet can not for the life of me figure out how to make a perfect fit piece. To be more so clear, I want to print a 3D grille block of perfect fit to my scan, but do not know how to make it without modeling it by hand perfectly to every point.
Have you encountered this challenge, or do you have an idea what may work?
Random info: MonoPrice Maker Select V2.0, Kinect V1, KScan3D, Meshmixer. Others downloaded and used, but this is where I'm feeling most comfortable right now. Print size is only 7.9^3 inches, so I will have to make these in pieces. My game plan (when I get there) is to make them like puzzle pieces, with those edges. . .
at an angle so they will only come out in one direction. Grille block will be easy (eventually), next step is extending the front end width to guide air around the tires, as well as filling the gap around the wheel wells. . . which will be much more challenging. The biggest, and final planned challenge at this time, is the rear wheel skirts. That's gonna be a lot of PLA (I'm not ready for ABS yet), and will need reinforcing, but hopefully will work well to fit right on, perfectly.
I am now contemplating making these pieces out of another material, scanning, and then printing them. At this point (two weeks of aggressive internet searching, one week just on this portion) I am taking a step back and looking at a different project while I try to cool down on my literal headaches of this current point.