Custom panel fabrication.

[gwl123]

Prohibitively expensive by hand from metal former/coachbuiler.
What options? I read where one can scan and have a manufacturer CAD it out and create the panels. Realistic? This not for a 911 body.

[buster73]

For small and simple parts you can use 3D-printed tools for sheet metal forming. In general you will need two molds/dies for both sides of the panel. Both dies are compressed with a hydraulic press (e.g. car jack) forming the sheet metal in the middle. Of course the low mechanical strength of the polymer tools will limit the achievable deformation of the sheet metal. You will not achieve the degree of bending, stretching and drawing possible with metal tools. Most parts I have seen were simple geometries with more or less 2-dimensional bending. Can be used with aluminum, mild steel or stainless and tools might be reused for a small number of parts (10 to 100).

[mepstein]

What do you want done? My metal guy outside of Baltimore is skilled and reasonable.

[gwl123]

I just want to replicate a car design on an existing chassis/frame (minor modifications). Dimensions are basic with lxwxh and wheelbase provided. Hoping a CAD software can extrapolate addition measurements.

I'll probably also need legal clarification if its a viable business project.