The interface where the center door frame locks into the front door frame is matched identically.
The 3d Printed piece fits perfectly.
With the design dimensions verified, the material itself had to be tested. PLA is the most common thermoplastic used today in 3D printing. However, it has a fairly low ‘glass transition’ point that was questionable to holding up to temperatures found inside cars on a hot day. Additionally, PLA does not hold up well to UV rays. Various test pieces were left outside on a 90* day, in direct sunlight for weeks on end and it was interesting to see PLA warp significantly. Carbon Fiber-infused PLA and PETG, as well as PETG itself held up great to UV rays and this heat.
Each setting from the build plate temperature, printer temperature, speed, layer height, retraction, etc.. all play a part in the finish product’s texture, dimensional accuracy, strength, and stiffness. Countless destructive tests of multiple brands of PLA and PETG were tested and compared to the strength of the OEM ABS plastic. Yes, OEM pieces were destroyed to ensure the new printed parts were stronger.
From this testing, slight changes in the design were necessary for use with the selected print material to surpass the strength and stiffness of the OEM part. The tab area was made thicker with thicker bracing, and the radiused edges were changed along with the shape of the interlocking ‘tabs’.