Man is 3D printing an entire Porsche GT3 RS using regular 3D printers

A Porsche Boxster is being turned into a Porsche GT3 RS through 3D printing, with every panel produced on $500 consumer 3D printers.

The project began with a 986-generation Porsche Boxster bought for $13,000 and a set of scan files that merge the Boxster chassis with GT3 RS dimensions.

Each body section is printed in smaller pieces, assembled, and reinforced before being fitted to the car.

The first panels have already reshaped the front end into the outline of a Porsche GT3 RS.

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3D printing a GT3 RS

This process was documented by Mike Lake via YouTube.

The Porsche GT3 RS is one of the most track-focused cars in Porsche’s lineup, but its price and limited allocation put it out of reach for most buyers.

Instead of securing one through official channels, one builder is using 3D printing to reproduce the car’s bodywork and mount it to a Porsche Boxster donor chassis.

Scan files provide accurate templates, allowing each part to be printed in sections that fit onto consumer machines.

The panels are produced in PETG filament, which is durable, heat-resistant, and relatively simple to work with.

Each part is printed in multiple segments, joined with plastic welding, and strengthened on the inside with fiberglass.

One fender for the Porsche GT3 RS took 55 hours of 3D printing and $40 in material.

The bonnet required 140 hours, while the front bumper consumed 380 hours and weighed more than 10 kilograms once complete.

The assembled panels have already been trial-fitted to the Porsche Boxster.

The 3D-printed Porsche GT3 RS components lined up closely with the donor chassis, and the wider stance of the GT3 RS became clear as soon as the front clip was taped and clamped into place.

What comes next

The next stage will focus on the rear quarter panels, the roof, and the interior.

These will be built using the same process, with 3D printing providing the parts before assembly and reinforcement.

The Porsche Boxster remains the mechanical base, while the new bodywork continues to move it closer to the profile of a Porsche GT3 RS.

Consumer 3D printers, once too limited for projects of this scale, are now being used to produce entire vehicle panels.

By combining digital scans with accessible equipment, the builder is progressing toward a full-scale replica of one of Porsche’s most exclusive models.

If completed, the car will be a Porsche GT3 RS lookalike constructed through 3D printing and fitted over a Porsche Boxster chassis.

It’s an unusual but detailed attempt to replicate a high-performance model with tools available to the public.

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