From Injection Moulded to 3D Printed: Custom Hubcap Replacement in Durban, South Africa.
When replacement parts are hard to find or no longer available, 3D printing offers a practical, cost‑effective solution. At Printer Under the Stairs, we specialise in custom 3D printed parts in Durban, helping customers replace small but essential components without needing to modify or replace an entire assembly.
Recently, a customer contacted us asking whether we could 3D print a replacement hubcap. The original part was no longer easily available, and sourcing a new one would have meant replacing the full wheel accessory set.
The customer sent us a physical sample of the original hubcap, and it was immediately clear that the part was injection moulded, not originally designed for 3D printing. This added complexity — but not a roadblock.
Reverse‑Engineering an Injection‑Moulded Hubcap
Injection‑moulded parts and 3D printed parts behave very differently.
Injection moulding allows for:
- Uniform wall thickness
- Internal geometries formed with specialised tooling
- High‑volume mass production
To recreate this successfully using additive manufacturing, we needed to redesign the hubcap specifically for 3D printing, while maintaining:
- Accurate dimensions
- Correct mounting points
- Reliable fitment
- The original visual appearance
Using professional CAD design software, we carefully modelled the hubcap from the sample provided. This wasn't a direct copy — it was a functional redesign, optimised for strength, durability, and print reliability.
The First Print: Learning from Orientation and Supports
Once the digital design was complete, we moved to printing the first prototype.
The initial print revealed several challenges:
- Minor surface inconsistencies
- Overhangs that didn't print as cleanly as required
- Areas where additional support was needed
In FDM 3D printing, orientation plays a critical role. The direction a part is printed affects:
- Layer adhesion and strength
- Surface finish
- Dimensional accuracy
- Long‑term durability
After reviewing the first print, we re‑oriented the hubcap on the print bed and strategically added additional support structures. These supports help stabilise overhangs during printing and prevent distortion while the material cools.
This adjustment significantly improved the outcome.
A Clean, Accurate Print with Perfect Fitment
The revised print produced a clean, strong, and visually accurate hubcap.
To ensure quality, we asked the customer to:
- Check fitment on the wheel
- Confirm alignment and mounting
- Approve the overall finish
The result:
- ✅ Perfect fit
- ✅ Secure installation
- ✅ No modification required
This step is essential in all custom work — a part isn't complete until it fits exactly as intended.
The Detail That Completed the Look: 3D Printed Silver Screws
While the hubcap itself was complete, there was still one detail missing.
The original hubcap used silver screws, and replacing them with standard black fasteners would have taken away from the final appearance. Instead of settling, we designed and 3D printed custom silver screws to match the original hardware.
This small detail made a noticeable difference, giving the finished hubcap a polished, professional look that closely matched the factory design.
It's attention to details like this that turns a functional part into a high‑quality replacement.
More Than Hubcaps: Small Custom Parts Made Easy
This project highlights what we do best at Printer Under the Stairs.
If you're struggling to find:
- Replacement automotive parts
- Small plastic components
- Custom caps, covers, clips, or mounts
- Parts no longer supported by manufacturers
We can help.
By working from:
- A physical sample
- Measurements
- Or a damaged original
we can design and produce custom 3D printed parts in Durban, with nationwide delivery across South Africa.
Your Local 3D Printing Partner in Durban
We are proudly based in Durban, serving:
- Individual customers
- Automotive enthusiasts
- Small businesses
- Repair and maintenance needs
While our focus is currently South Africa, our processes are built to scale — allowing us to support wider (sub-saharan African) regions in the future as demand grows.
If you need precision 3D printing, custom part design, or reliable replacement components, we're ready to help.
