Akmal Azhar
From Boxster to GT3 RS
A 986-generation Porsche Boxster is being reshaped into a GT3 RS using 3D printing technology. The project began with a $13,000 donor car and scan files that merge the Boxster’s chassis with the dimensions of a GT3 RS. The builder prints the car body in smaller sections, reinforces them, and mounts them onto the Boxster. Already, the front end has taken on the aggressive stance of a GT3 RS.
The Builder and His Method
The work is being documented on YouTube by Mike Lake, who chose to reconstruct the GT3 RS bodywork rather than buying the real thing. Using scan files as a template, each body part is printed with consumer-grade machines and then shaped to precise dimensions. The chosen material is PETG filament, known for its durability, heat resistance, and ease of use. After printing, pieces are plastic-welded together and reinforced with fiberglass for added strength.
Time and Effort Behind Each Panel
Every section of the car requires hundreds of hours of printing and assembly. A single fender takes 55 hours and $40 worth of material. The bonnet requires 140 hours, while the front bumper demands a massive 380 hours and weighs over 10 kilograms. Once fitted to the chassis, the wider stance of the GT3 RS becomes clearly visible.
Next Steps in the Build
With the front section already resembling the GT3 RS, the builder will next tackle the rear quarter panels, roof, and interior. The same process of scanning, printing, welding, and reinforcement will be used. As the build progresses, the Boxster continues to provide the mechanical backbone while the 3D-printed bodywork gradually transforms it into a convincing GT3 RS replica.
A Glimpse of Accessible Innovation
This ambitious project highlights how consumer-level technology can achieve what once seemed impossible. With $500 printers, digital scanning, and patience, enthusiasts can replicate complex designs like the Porsche GT3 RS. What began as a modest Boxster is slowly evolving into a 3D-printed masterpiece, bridging creativity and engineering in the automotive world.
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