Prompted by his son's request, Backus employed 3D-printing systems to produce a range of parts of the supercar, including body panels, taillights, interior parts, headlights, and air vents.
The components were created using 220 spools of thermoplastics and assembled with outsourced automobile parts, like the main chassis and engine.
Notably, some structural pieces such as the door's inner structure were also sourced from outside.
Plus, 3D-printed parts were encapsulated with carbon fiber
Before assembling the 3D-printed parts with outsourced ones on a steel frame, Backus had to ensure that the vehicle is strong enough and safe.
For this, he used carbon fiber vacuum infusion and encapsulation techniques and wrapped all printed components in carbon fiber.
The duo also employed CNC machining and waterjet cutting to bring the life-sized Aventador-like model to life.
Over $20,000 invested in the project till date
Over the last one and half years, Backus and his son have invested nearly $20,000 into the supercar's development. They have sourced parts from eBay and Lamborghini suppliers, with the engine coming from a 2003 Chevrolet Corvette and transaxle from a Porsche 911.
Will this raise copyright issues?
While the project looks extremely interesting, Lamborghini, a world-famous automobile brand, may not like the idea of its work being imitated.
The 3D-printed Lamborghini could raise copyright issues, but Backus claims they "have changed each panel significantly, to add our [personal] design flair."
"In addition, no molds are made, and none are for sale. This is a one only project," he further noted.
Work is still in progress
Having said that, it's worth noting that the 3D-printed Lamborghini is still being developed. The father-son duo work on the car daily and occasionally show the car at "schools as a STEAM project, to get kids interested in Science, Technology, Engineering, Art, and Math." You can follow him on Facebook: https://www.facebook.com/lasersterling/