01 / Challenge
Challenge
An EV charging startup needed an outdoor-rated port cover prototype that could pass a UV and cycling test before tooling was committed.
Pre-Production Prototype — 2025
EV Charge Port Cover
A weather-sealed charge port door printed in ASA, cycled ten thousand times and left on a rooftop for a summer without fading.
ASAFDMAutomotive
Preparing 3D view
Loading geometry and materials.
- Project
- EV Charge Port Cover
- Material
- ASA
- Technology
- FDM
- Print Time
- 7 hours
- Layer Height
- 0.16 mm
- Weight
- 88 g
- Dimensions
- 145 x 130 x 42 mm
- Industry
- Automotive
02 / Design
Design
A living hinge was replaced with a printed pin hinge after the first revision cracked. TPU was co-printed as a perimeter gasket to seal against the housing.
03 / Printing Process
Printing Process
ASA printed at 0.16 mm in an enclosed chamber to prevent warping, with the TPU gasket printed separately and press-fitted.
04 / Final Result
Final Result
Ten thousand open-close cycles with no hinge failure, and no measurable colour shift after a full summer of rooftop UV exposure.
Gallery
Through the build
Four moments from the job, in the order they happened.
- 01
Pin hinge detail - 02
TPU gasket in place - 03
Cycling rig - 04
After a summer of UV exposure
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EV Charge Port Cover
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