This project at the automotive customization shop Ai Design was for an awesome client with a fleet of unique vehicles.
Our team converted his Audi B5 RS4 Avant into an overland-kitted all-road Safari wagon. Shown here are two parts we fabricated for the front bumper - a light bar in anodized aluminum, and a lower grill in PC-ABS.
For the light bar, our shop owner Matt and I worked together on the design, an offset bumper-hugging curved form with some angularity, to integrate smoothly into the vehicle’s look and feel, and fit within our client’s aesthetic as well.
The bumper’s compound curves would be the only points of surface contact for this part, so I started with 3D scans of the bumper, then designed most of the light bar in CAD.
We 3D-printed a prototype in ABS to test fitment and placement, then we outsourced the aluminum machining to a trusted partner, who milled it on a multi-axis CNC machine. It was then vapor-honed and anodized.
For the bumper’s lower grille, I CAD-modeled the overall shape, recreated the diamond pattern, and matched attachment points the original OEM grille, then added an opening for an additional light and our client’s logo badge. We printed this in PC-ABS.
On the rear bumper, we also designed and 3D-printed a corresponding center grille to house additional reverse lamps, further amplifying the all-road agility of this wicked RS4.