Remanufacturing a VW Golf 2 Throttle Lever with 3D Scanning and PA12-CF15 Printing

Sourcing parts for aging vehicles is a familiar challenge for every mechanic and restorer. The Volkswagen Golf 2’s throttle lever is a typical example: it’s no longer mass-produced — but with modern digital manufacturing, it can be recreated precisely, to the original dimensions.

1. Digitizing the Throttle Lever: 3D Scanning

The first step of the project was digitizing the exact geometry. The throttle lever’s complex curves and critically positioned, precise bores made 3D scanning the right choice. We performed a fast scan, sufficient for reverse-modeling the overall dimensions, using a RevoPoint POP 3 infrared scanner — a cost-effective, quick solution that met the accuracy the project required.

• Mounting and positioning the sample for the scanner
• Performing the scan, then cleaning up the digital model and fixing errors
• A high-accuracy STL model with the complete geometric information

2. Reverse-Modeling: CAD Design

We built up the CAD model from the scanned data in several stages. First, we printed a simple prototype in Creality Hyper PLA, which let us compare the critical dimensions — curves, bore positions — against the original, and test-fit it onto the carburetor to check the fit.

On the next, more detailed piece, we refined the Bowden cable groove and the mounting points, then finalized the design based on client feedback. Since we were designing for 3D printing, we modeled the structure thicker than the original — while preserving the underlying geometry to keep the original function intact.

• Refining the bore dimensions for a tighter fit
• Added ribbing at the fracture-prone line for durability
• Preserving the original functionality alongside the reinforcement

3. Manufacturing: Material Selection and FDM Printing

The client had three main requirements: good heat resistance, adequate mechanical properties, and chemical resistance. We chose Fiberlogy PA12-CF15, a carbon-fiber composite — a material family also used by automakers themselves for engine-bay components.

• ~175°C heat resistance for the engine-bay environment
• Excellent mechanical properties and stiffness
• Resistant to hydraulic fluids, fuels, and greases

We used FDM technology for manufacturing, with a 0.2 mm layer height, a 0.4 mm nozzle, and 100% infill. After support removal and deburring, the carbon-fiber surface gave the part a distinctive look and effectively hid the layer lines.

The end result surpassed the original part both functionally and aesthetically.

Summary

This project is a good example of how the combination of 3D scanning, reverse-modeling, and 3D printing provides an effective answer for custom and discontinued automotive parts. If you need to remanufacture an old or custom part, get in touch for a quote on our industrial 3D scanning, design, and printing services.