Aero Minor Le Mans Back in Racing Form Thanks to 3D Scanning and 3D Printing

Modern technology is returning classic vintage cars to the track. Thanks to 3D scanning, we can create precise digital copies of components that have long been out of production and lack manufacturing documentation. With 3D printing, necessary parts can be custom-made, even as single units, without the need for expensive molds. One such vehicle that excelled in the post-war era and continues to race today with the help of 3D technology is the Aero Minor Sport.

The Czechoslovak "Cigar" Surprised Le Mans

The Aero Minor Sport represents a sensational entry for Czechoslovaks into post-war racing history. This small, lightweight two-seater "formula" car achieved a level of success at the legendary Le Mans in the late 1940s that remains essentially unsurpassed by any other Czech machine or driver.

The car was extremely light, weighing just over 400 kilograms, and nearly every part—except for the fuel pump—was purely Czechoslovak. It was powered by a 745 cm³ two-stroke, two-cylinder engine producing approximately 22 kW (just over 30 hp). Despite the modest power, its light weight allowed it to reach speeds of around 130 km/h, making it a perfect fit for the under-750 cm³ racing category.

Custom Spare Part from Powdered Nylon

A specific mechanical issue arose when the starter coil began to fail. Research revealed that the car used a custom-modified starter where the flange had been rotated so the bolt holes were oriented differently, preventing the coil from touching the engine block and overheating.

To fix this:
Technicians took a standard flange and scanned it.
The scan was converted into a 3D parametric model, where the bolt holes were moved to the correct positions.
The modified part was printed on a Formlabs Fuse 3D printer using powdered nylon.

This nylon material provides the necessary strength, durability, and resistance to vibrations required for racing. This 3D-printed plastic flange has now been functioning reliably in the car for over a year, including during races at Le Mans.

The flange was first scanned, modified in a 3D CAD program according to the specifications, and then 3D-printed from powder using a Formlabs Fuse 3D printer. It continues to serve reliably on the vintage race car to this day.

The Benefits of Additive Manufacturing

The story of the Minor demonstrates that 3D printing is often about more than just saving money; it’s about solving problems that would otherwise leave a machine inoperable. It provides designers with creative freedom to produce parts that have disappeared from catalogs or to manufacture complex geometries that are impossible to create with traditional methods.

By using 3D printing:

• Expensive molds are eliminated.

• There is no long wait for external suppliers.

• There is no need to maintain large inventories of spare parts.

• Modern materials like powdered nylon are durable enough for the harsh pace of racing.

This technology has evolved from a "technological toy" into the most logical and efficient solution for manufacturing challenges in the automotive industry and beyond.