Delivering Precision and Scale for Classic Car Restorations

Retropower, renowned for their high-end automotive restorations, initially came to Prototal looking for larger, higher-quality parts than they could produce in-house.

Their in-house setup couldn’t accommodate the size or finish required for key components such as the front grille and other interior parts. Their experience with carbon-filled nylon printed on their own equipment had been inconsistent and limited by machine capacity.

They were facing several challenges:

Build volume limitations – unable to produce large parts in one piece.
Inconsistent quality and poor surface finish.
Previous poor supplier experience, lacking transparency and technical support.
Difficulty achieving precise tolerances for functional parts.

The Prototal Solution

Prototal UK stepped in to address all three priorities: finish, quality and build size.

Our team recommended SLS in Nylon 12, a material Retropower were already familiar with, but which we could process to a far higher standard using our industrial-grade equipment. The parts were then dyed black and vapour smoothed, achieving a clean, consistent surface that reflected the quality of Retropower’s builds.

We produced several key components for their projects, including:

Audi Quattro Front grille assemblies – manufactured in one piece thanks to our large-format SLS systems.
Jenson interceptor intake pipes – manufactured with a consistent 3mm wall thickness with one to one accuracy resulting in a perfectly fitting complex duct design.
Allegro demister duct components – reproduced with a texture nearly identical to the original 1990s finish, meeting both functional and aesthetic requirements.

In addition to delivering the physical parts, our collaborative approach was key. Prototal UK provided:

Transparent communication – clear updates, advice and process explanations.
Technical recommendations – helping Retropower make confident material and design decisions.
Access to the full Prototal Group network – if a specific material or technology wasn’t available at our UK site, we could coordinate production through one of our European sister companies, ensuring Retropower always had access to the best possible solution.

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How We Helped

The Result

Through this collaboration, Prototal solved both the quality and build size challenges that had held Retropower back.

Key outcomes included:

Large, high-quality parts produced to specifications.
Improved surface finish and visual consistency through vapour smoothing.
Reliable dimensional accuracy – e.g., the Jenson intake ducts
Textured parts (such as Allegro demister duct component that authentically matched the car’s original design).
A smooth, transparent service experience with clear communication throughout.

Beyond resolving the technical limitations, Retropower valued Prototal’s partnership-driven approach – knowing that they now have a trusted manufacturing partner with access to an entire European network of additive and traditional technologies, including metal production through CA Models, which is something they are looking into for future projects.

Key Outcomes

Solved quality and build size challenges.
Delivered premium SLS Nylon 12 components with OEM level surface finish.
Achieved tight tolerances and precise fit on functional parts.
Provided transparent communication and technical support.
Enabled access to wider Prototal Group capabilities across Europe.

Delivering Precision and Scale for Classic Car Restorations