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August 5, 2013

New Zealander prints replica Aston Martin DB4

Because the printer isn't big enough to print large pieces in one go, Sentch has printed around 2500 separate sections.

By Amy-Jo Crowley

A computer programmer from New Zealand has begun printing plastic parts to form a 1961 Series II Aston Martin DB4.

Ivan Sentch has been working since January 2013 on the replica, which will cost a fraction of the price of a real Aston Martin worth between £220,000 to £1.2m.

Sentch, who has no previous experience of 3D printing, began the process of printing out individual 4-by-4-inch sections, then mounting them on the wooden frame and gluing each piece into place.

So far, with 2,500 fiberglass molds printed, he is currently 72% of the way to completion.

In an interview with MAKE magazine, he said: "I was told to expect $12K to $15K NZD for a CNC-cut plug, which nearly killed the project idea but, somehow, I had the thought to look into 3D printing as an alternative and, after researching it, it was only going to cost me $2K in plastic and the cost of the printer, which I can use for other things like making a replica dash and what not."

Sentch, who expects to finish the project within four or five years, still has to develop the dash and other interior and exterior bits as well as sanding, and painting.

His website, Replica DB4 Project, has reported on the project since he started it in his garage and how has an international following.

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