From Idea to Reality: Creating Our Lando Norris F1 Display Frame 🏎️

Written By Devang Gandhi

From Concept to Production – Lando Norris F1 Display Frame

At Penrose 3D, we specialise in turning ideas into reality using additive manufacturing, from early-stage concepts to fully realised products.

This project started with a simple question:
Can we create a premium, display-worthy piece for Formula 1 fans using 3D printing?

What followed was a full journey through design, prototyping, and production.

💡 The Idea: A Display Worthy of Formula 1

As F1 fans, we wanted to create something more than just a model - a centrepiece.

The goal was to design a display that felt:

  • Premium and minimal

  • Structurally strong

  • Functional with integrated lighting

  • Easy to maintain

This wasn’t just about aesthetic, it needed to be engineered properly.

🧠 Design & CAD Development (DfAM in Action)

Using Fusion 360, we designed the frame from the ground up with Design for Additive Manufacturing (DfAM) principles.

Key considerations included:

  • Eliminating the need for glue or weak joints

  • Integrating the battery housing directly into the design

  • Hidden fixings for a clean external finish

  • Optimising geometry for print strength and consistency

Every feature had to serve both form and function.

CAD screenshot

🔁 Prototyping & Iteration

No product is perfect on the first attempt and this was no exception.

Through multiple iterations, we refined:

  • Part strength and rigidity

  • Dimensional accuracy and tolerances

  • Print orientation for surface quality

  • Assembly simplification

One of the biggest breakthroughs was moving to a single-piece frame design, which:

  • Improved structural integrity

  • Reduced post-processing

  • Increased production consistency

Early prints and testing of LED Strip Integration and material choices

🧵 Material Selection

Material choice plays a critical role in additive manufacturing.

For this project, we prioritised:

  • High-quality surface finish

  • Strength and durability

  • Reliable, repeatable print performance

This ensured the final product not only looked premium but performed like it too.

⚙️ From Prototype to Production

Once the design was validated, we transitioned into batch production.

Our production process focused on:

  • Repeatability across multiple units

  • Tight quality control

  • Efficient print workflows

Each unit is:

  • Manufactured in-house in the UK 🇬🇧

  • Carefully inspected for quality

  • Assembled with integrated LED lighting

✨ Final Product Features

The finished display frame includes:

  • Premium matte finish 3D printed frame

  • High-quality Silverstone circuit display board

  • 1:43 scale Lando Norris MCL39 (2025 season)

  • Integrated LED lighting (powered by 3x AA batteries – not included)

  • Rear access with integrated fixings

  • Dimensions: 290 (L) x 205 (W) x 85 (D) mm

Perfect for:

  • Office desks

  • Display shelves

  • Gifts for Formula 1 fans

🚀 What This Project Demonstrates

This project highlights the true potential of 3D printing for end-use products, not just prototypes.

It demonstrates:

  • Rapid prototyping and iteration

  • Design for additive manufacturing (DfAM)

  • Seamless transition from concept to production

  • High-quality, UK-based batch manufacturing

🤝 Looking to Develop Your Own Product?

Whether you're:

  • Developing a new product

  • Creating a functional prototype

  • Looking for small batch manufacturing

We can help bring your idea to life.

👉 From design → prototype → production

📩 info@penrose3d.com
🌐 www.penrose3d.com

Start Your Project
Devang Gandhi