Exhaust fabrication

I developed a 3D printable LEGO-style mockup kit to make manufacturing exhaust headers easier. 

Inspired by off-the-shelf kits that can retail for over $1000, my kit was made from less than $40 worth of filament and streamlined the design and manufacturing process greatly. 

This was an excellent case study for parametric design since this kit can now be scaled to almost any size and shape tubing.

For something more organic like headers, it's very helpful to bring it into the real world. Being able to play around and experiment with shapes can let you come up with configurations you would have never thought of in CAD. 

Manufacturing was made easy with printed jigs matching the exhaust port dimensions. Welding on the fixture table was easy (or at least easier than it would have been on the car) and minimzed warping.