HOW TO 3D PRINT AN AERODISC: STEP-BY-STEP GUIDE

Buying new wheels can cost thousands — but with a 3D printer and some simple CAD, you can design and print custom aero discs for a fraction of the price.

🎁 3d Printed Aerodisc FREE Download: Use our premade Aerodisc to speed up your custom design. The design features:

✅ A center snap in cap
✅ Aerodisc like fins
✅ Fits on a 256x256mm 3d print bed

⬇️ Grab the editable Shapr3D CAD file here

In this guide, I’ll walk you through exactly how I designed, prototyped, and 3D printed custom aero discs using Shapr3D and a Bambu Lab 3d printer.

STEP 1: MEASURE YOUR WHEEL

Start with accurate measurements. The best place to mount the aerodisc onto our BMW bottle cap rims will be the center wheel cap.

• Use a digital caliper to measure the inner diameter and depth of your wheel’s center cap area for mounting.

💡 PRO TIP: Check your measurements and design starting from the inside dimensions outward.

STEP 2: MODIFY THE DESIGN IN SHAPR3D

Open Shapr3D and import the free shapr3d CAD file.

1. You can the history tool on the right hand side to open and modify the dimensions.

2. Select the inner ring and modify the diameter, the entire design will adjust based on a change made with the history tool.

STEP 3: PROTOTYPE WITH A TEST PRINT

Before going big, I like to do a test print for fitment. This can be with lower grade filament before doing the final print in more expensive UV and heat resistant filament.

1. Hide the Aerodisc fins in shapr3d along with the circular plate.

2. Reduce the extrusion of the cylinder.

3. Test print the part and check the fitment of the clips.

• Print on a Bambu Lab A1 (or any entry-level printer) for prototypes

• Use leftover or low cost filament like PLA — this is just for fitment.

• Expect to fail a few times. My first version didn’t fit until I adjusted the design and added snap-in clips.

STEP 5: PRINT IN ABS + ADD CUSTOM DESIGNS

For the final part, switch to ABS filament on an enclosed printer like the Bambu Lab P1S, or larger H2S.

• ABS resists heat from sunlight.

• Use ChatGTP to create logos or patterns and ask ChatGPT to export in SVG

• Import the SVG along with the Shapr3d STL into Bambu Studio, assign colors, and merge layers for a clean print.

I used black ABS for the disc and white ABS for different patterns that ChatGTP created.

Pro Tip: If you need help picking a 3d printer, check out our filament and 3d printer selector for car parts [here]

STEP 6: ASSEMBLE AND TEST

Snap the aero disc into your wheel and check the fitment

• The clips should lock the Aerodisc into place

• If needed, adjust the CAD file in Shapr3d history mode and reprint.

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