Case Study: Jay Leno’s Garage achieves an antique valve-cover replacement at one-tenth the cost with 3D Systems’ scan-to-CAD and On Demand Manufacturing

Jay Leno’s Garage Replaces Antique Car Part for 1/10th the Cost with 3D Systems' Solutions

Jay Leno’s Garage faced the challenge of repairing a severely corroded valve cover on a 1916 Owen Magnetic—an early gas‑electric hybrid—for which replacement parts no longer exist and prior repair attempts had failed. The team needed an economical, authentic replacement that improved durability and appearance without the cost and lead time of traditional methods.

Using a scan‑to‑CAD workflow (FARO® Design ScanArm into Geomagic Design X™) and 3D Systems’ 3D Modeling and On Demand Manufacturing services, the part was reverse‑engineered, improved for strength and alignment, printed as an SLA QuickCast® investment casting pattern, and cast in aluminum by SeaCast. The digital approach delivered a functional, museum‑quality valve cover with smoother surfaces and structural upgrades at roughly one‑tenth the cost of conventional methods, restoring the car for many more years of use.

Jay Leno’s Garage

Jay Leno

Jay Leno’s Garage