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Playing Forza inspired this gamer to 3D-print a Lamborghini for his son

Colorado physicist Sterling Backus has leveraged technology and creativity to put an Aventador S in his garage without sending Lamborghini a $400,000 check. Working with his son, he is in the process of making the supercar from scratch using 3D-printed panels and used parts purchased online.

Backus launched the project after his son fell in love with the Aventador S while playing Forza Horizon 3. He told Australian website Which Car he initially wanted to make the supercar using steel panels and a wooden buck, but he decided to take the 3D-printing route after seeing how far the technology had come.

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He draws each panel on software called Solidworks, prints them in several pieces using three printers, and glues them together. This technique is time-consuming, but he didn’t want to purchase an expensive, industrial-sized machine. The father-and-son team then wraps each assembled panel in Kevlar for added strength, and to achieve a uniform look. The finished body panels are then attached to a tubular steel frame.

 

Backus isn’t a 3D-printing expert by any means; he learned a lot by watching informative videos on YouTube. He’s not an automotive engineer, either, but he designed the chassis himself — a task automakers normally spend millions of dollars on — and even created a suspension system inspired by the setup found on the real Aventador S.

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It’s not possible to 3D-print a fully functional engine, at least not yet, and Backus quickly ruled out buying a naturally aspirated, 6.5-liter V12 engine from Lamborghini. Instead, his Aventador replica will be powered by a V8 engine sourced from a 2003 Chevrolet Corvette and upgraded with a pair of turbochargers. It will be mounted behind the passenger compartment, like in the real Aventador, and it will spin the rear wheels through a transaxle from a 1990s Porsche 911. He sourced other parts (like the steering wheel, the windshield wipers, and the switches) used from online vendors.

Assembling a supercar using 3D-printed panels, a Chevrolet engine, a Porsche transaxle, and various bits and pieces from other manufacturers isn’t as straightforward as going to the nearest Lamborghini dealer with a suitcase full of cash. It’s a rewarding experience, however, and it’s much cheaper. Backus expects the entire project — which you can follow on his YouTube channel and on his Facebook page — will cost less than $20,000.

Ronan Glon
Former Digital Trends Contributor
Ronan Glon is an American automotive and tech journalist based in southern France. As a long-time contributor to Digital…
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