Scan and measure
We 3D-scanned the original box and used the scan as a measuring reference for its shape, flange and fixing points. The charging socket was measured with a vernier calliper.
Case study · Lotus
Adding USB charging to a Lotus Esprit oddments box
A drop-in oddments box with a modern USB charging socket, made so the car’s original box stays untouched and the console can go back to standard at any time.
- Vehicle
- Lotus Esprit SE (highwing)
- Part
- Centre console oddments box
- Material
- ASA-CF, with a TPU mat
- Process
- 3D scan · CAD · 3D print
The part
The Lotus Esprit SE has a small oddments box in the centre console, just below the heater controls. On the SE it’s a plain storage tray. Later Esprit S4 models have a cigarette lighter there, which can be used for USB charging. This owner wanted to charge a phone in the centre of the car, but the S4 box is no longer available, and they had searched for a second-hand one without success. Just as important, they wanted to keep the original box exactly as it was, with no drilled holes and nothing bonded to it, so the console could be returned to standard at any time. Starting from a scan of that box, we designed a new one that fits the same slot and carries the socket instead.
The challenge
The new box had to slot into the console in place of the original, with no changes to the car, while holding a socket the original was never designed for:
- the flange that sits against the console face;
- the two tabs and the screw hole that locate and fix it in place;
- a flat panel to mount the socket, without giving up too much storage space.
Our approach
Redesign around the socket
We modelled a new box in professional CAD, keeping the original’s flange, tabs and screw hole. One end of the opening became a recessed panel with a 29 mm hole for the socket, and the storage bay was narrowed to make room for it.
Check the fit
We laid the new model (grey) over the original scan (blue). They match closely where the box meets the car, and differ on purpose where the shape changes to make room for the socket. Then we printed it and test-fitted it in the car.
A mat for the base
We also designed a textured mat for the base of the box, printed in flexible TPU.
The result
A drop-in oddments box that fits the console’s existing slot like the original and holds a USB charging socket, so the owner can charge a phone in the centre of the car. The original box is left untouched, so the car can be returned to standard whenever the owner chooses. Because the new box exists as a precise digital model, another can be printed on demand.
Take it with you
The full two-page case study, with more photos and detail.
Obsolete isn’t the end.
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