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This is a project which stemmed from demand of a product which is no longer available. I own a 1986 BMW 325ES and I enjoy working on the car and constantly trying to improve upon it. During the time I was restoring the BMW I needed these brackets to hold the front valence onto the bumper. The ones I had were beyond repair and cracked; when i tried to find new ones I found that BMW and all of the OEM suppliers had stopped manufacturing them. So I designed a new set of brackets very similar to the old set but with a few key changes. I thickened the ribs on the bracket and added larger fillets to all of the angles. After which I conducted FEA simulations on the brackets to test for strength. I then proceded to find a machine shop that could machine the brackets for me from 6061-T6 aluminum or ABS plastic. Unfortunately I was unable to source a machine shop which could machine the brackets at a affordable rate. Hence I purchased a 3D printer and printed the brackets from Petg filament. I installed the brackets onto my car and drove approximately 10,000 miles in a span of 3 months, 500 of which were intentionally over rough terrain. After testing the brackets I removed them and did a thorough inspection for cracks and any signs of failure; I was unable to find any. So I then began printing larger batches of the brackets and began selling them to fellow BMW enthusiasts through Facebook Marketplace and BMW forums.
I have been taking feedback from all customers and so far have received excellent feedback and continue to produce these to sell.
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