Reverse engineering · CAD creation · 3D printing

You define it,
we make it.

At JC Additive we can take your ideas or old worn-out parts, create them as precise CAD models, and reprint them in engineering-grade materials — from automotive trims to one-off products and prototypes.

Request a quote See the portfolio
Run by a professional automotive and motorsport engineer Formula 1 experience Based in Norfolk, UK
FIELD RESULT · DWG JCA-001 DRAG TO COMPARE
The reverse engineered deflector fitted under the rear arch, printed in black ASA
The original deflector cracked and hanging loose under the same arch
PartDeflector
MaterialASA
CADOnshape
StatusIn service
The method

Three steps from broken to better

Every job starts in one of two places: a part that exists but can't be easily sourced, or an idea that doesn't exist yet.

01 · Measure

Capture the part or idea

An existing part gets measured precisely. A new idea is born from a sketch, a photo, or a conversation about what it needs to do. Both end in the same place: a clear definition of the requirements.

TOOLS: REFERENCE PHOTOGRAPHY · FIRST-PRINCIPLES ANALYSIS
02 · Model

Build it in CAD

Everything becomes a fully parametric model. For a remade part, design flaws engineered out. For a new design, it's where an idea becomes something that can actually be made.

TOOLS: ONSHAPE PARAMETRIC CAD · TOLERANCE ANALYSIS
03 · Print

Print in the right material

The part is printed on modern high-speed FDM equipment in a material matched to its job — UV-stable ASA for exterior automotive parts, tough PETG for functional pieces, PLA for display work.

TOOLS: BAMBU LAB P2S · ASA / PETG / PLA
Portfolio

Recent work, stage by stage

Every project below can be stepped through from the original problem to the finished part. Click a stage to follow it.

CASE STUDY 001 · REAR WHEEL DEFLECTORSHEET 1/1
The original deflector cracked and hanging away from its mounting clips under the rear arch of a red Ford Fiesta The original deflector removed and laid out on a bench in pieces, with its broken metal clips separated The rebuilt deflector as a parametric CAD model in Onshape, showing the clip pockets and locating ribs The freshly printed yellow deflector beside the worn black original on a Bambu Lab build plate The final deflector printed in black ASA, fitted under the rear arch of the Fiesta
01 / 05The original had cracked and pulled away from its mounting clips — and a replacement proved hard to source.
Reverse engineered

Ford Fiesta aero wheel deflector

The original had worn through and the OEM part was difficult to source directly. What was left of it was measured, rebuilt as a parametric CAD model, and reprinted in UV-stable ASA — a like-for-like replacement engineered from first principles.

Because the model is parametric rather than a scan, the same part can be reprinted at any time, in any material, or further modifications made to enhance its performance.

MaterialASA
CADOnshape
SectorAutomotive
Time2 days
CASE STUDY 002SHEET 1/1
The question block lamp modelled in Onshape, showing the shell and cut-through question mark panels The lamp part-printed in yellow and white on a Bambu Lab P2S with the AMS 2 Pro loaded above The finished question block lamp glowing warm orange in a dark room
01 / 03Modelled from scratch in Onshape — a hollow shell with the question marks cut clean through the walls.
Product design

Question Block LED lamp

A retro gaming lamp designed from scratch in CAD — multi-material construction, light-diffusing panels and integrated LED lighting. Proof that the same precision behind engineering parts makes products worth putting on a shelf.

MaterialPLA
SectorConsumer
CADOnshape
Time2 days
CASE STUDY 003SHEET 1/1
The name tag keyring modelled in Onshape with raised lettering and a star charm The finished yellow name tag with a star charm clipped to a school backpack zip
01 / 02Built parametrically, so a new name is a text field to change — not a part to redesign.
Custom small batch

Personalised backpack keyrings

Durable, personalised name tags designed for a school backpack — and for surviving a school year. Names, colours, charms and shapes made to order, from one to a hundred.

MaterialPLA
SectorPersonal
CADOnshape
Time0.5 days
CASE STUDY 004SHEET 1/1
The workshop drawer unit modelled in Onshape, showing four numbered drawers and scalloped finger pulls The printed blue-and-white drawer unit in use beside the printer, holding tools, filament and glue
01 / 02Designed around the exact kit it holds — drawer heights, dividers and finger pulls all set in CAD.
Bespoke design

Workshop tool drawers

A drawer unit built for my own bench — sized around the tools and filament it stores, with handles shaped to my hands. When you design the part rather than buy it off a shelf, it fits exactly what it's for.

MaterialPLA
SectorWorkshop
CADOnshape
Time1 day
Capabilities

Engineered, not just printed

Jack Chilvers, founder of JC Additive
About

Jack Chilvers MEng MSc

Founder · Aerodynamicist

I'm an aerodynamicist with over a decade of motorsport and automotive experience. My working life is spent measuring, modelling and improving the shapes of cars — first in Formula 1 at Renault Sport Racing and Williams Racing, and now leading aerodynamics development at a global vehicle manufacturer.

JC Additive was founded through a passion for engineering and what is now possible in the realms of 3D printing. Whether its making functional parts or display items, I draw on years of CAD experience to transform ideas into working models ready for printing.

If you're struggling to source an OEM part for your project or simply have a novel idea which requires engineering and manufacturing, then let's discuss how we can make it a reality...

  • Formula 1Renault Sport Racing · Williams Racing
  • CurrentLead Aerodynamics Engineer, global OEM
  • TeachingVisiting Lecturer in CFD, Cranfield University
  • WorkshopNorfolk, UK · shipping nationwide
Start a job

Got a project in mind?

Let's discuss it further. Simply send across a description, sketch or photo of your idea or existing part and I'll give you an honest answer on whether we can help without obligation - usually within 48 hours.

  • Send photos, sketches or ideas
  • Receive a fixed quote and lead time
  • Approve the CAD preview before printing
Email a quote request

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