Practical guide · 8 min read

How to replace a broken part with 3D printing

Is a plastic part broken, worn out or impossible to find? 3D printing can reproduce it to the same dimensions, or even improve it, and this guide takes you through the whole process, from the first message to the delivered part.

When 3D printing is the right way to replace a part

3D printing isn't the answer to everything, but it does well in situations where the usual routes fail.

Obsolete plastic part

The manufacturer no longer makes it and it isn't in any replacement parts catalogue.

Spare parts no longer available

Your appliance is an older model and its spare parts have been discontinued.

Old or vintage model

A classic car, an industrial machine, a retro device: the original parts no longer exist.

A specific part you can't find

A made-to-measure part, a one-off model or a handmade object with no standard replacement.

Can't buy just one

The manufacturer only sells the part in bulk packs or sets an excessive minimum order.

Urgent repair

You need the part quickly and the supplier's lead times are too long.

Strengthen a weak design, or check a shape before moulding

If the original part was fragile, we can make the copy thicker or add reinforcement where it broke. 3D printing also suits a prototype or a pre-series: you check the shape on a printed part before paying for an industrial mould, which takes far longer to make.

Reproducing a broken part in 4 steps

1
Send the part, photos or measurements
Send us the broken part (even in pieces), detailed photos from several angles, or a dimensioned sketch. Ideally, photograph it next to a ruler for scale, note the critical dimensions (hole diameters, thicknesses) and tell us how it is used: where it fits and what loads it takes. The more we know, the closer the copy.
2
Custom CAD modelling
We create a 3D model of your part in CAD (computer-aided design) software, keeping every dimension and every functional detail. For mechanical parts, we build in the fit tolerances. You receive a file to approve before anything is printed.
3
Choosing the right material
Depending on the job the part does, we recommend PLA for decorative parts, PETG for mechanical parts and TPU for flexible ones. The material is what makes a replacement part last, and we'll tell you plainly if 3D printing isn't the right solution.
4
Printing and delivery
The part is printed with settings tuned to the material and its use, then its dimensions are checked. If needed, we first print a quick prototype to confirm the measurements before the final part. You collect it in Toulouse or we send it to you.

Which material to replace which part?

The right material is what lets your replacement part do its job. Here's what we recommend for each type of part.

Original part	Material	Why
Clip, cover, trim, grille, knob	PLA	Rigid, accurate, clean finish. For decorative parts or clips that don't take repeated mechanical stress, away from heat.
Gear, hinge, bracket, housing	PETG	Resists impacts and heat (up to about 80 °C). Right for functional and mechanical parts under load, including car and motorbike parts.
Seal, shock absorber, cable grommet, foot	TPU	Flexible and shock-absorbing. Replaces rubber or silicone parts and non-slip feet, with good wear resistance.

Examples of reproduced parts

Car dashboard vent cover

On an older vehicle, the vent cover was cracked and no supplier still stocked it. Reproduced in black PLA, it fits like the original.

Appliance fixing clip

A broken dishwasher door clip that the manufacturer only sold in packs of 100, at €0.50 each. We printed a single one, in PETG for extra strength.

Part from an old industrial machine

A gear from a 1980s machine tool, out of production for 20 years. Modelled from the worn part and printed in PETG.

Broken furniture handle

A handle from a designer piece of furniture that is no longer sold. Reproduced in PLA, then sanded and painted to match the others.

More detail on each plastic in our materials guide, and more examples on our car and motorbike parts page.

Limits of 3D printed replacement parts

We'd rather tell you up front than promise a disappointing result. Here is when FDM printing is not the best solution.

Situation	Why it's a problem
Prolonged contact with food	FDM plastics are not certified for repeated food contact: there is micro-porosity between the layers.
Strong heat	PLA can warp above about 60 °C. PETG holds up to about 80 °C; beyond that, FDM plastics deform and another solution is needed.
Replacing metal parts, heavy loads	Printed plastic doesn't replace metal for parts under heavy load or wear, and FDM has limits in fatigue and shear. For critical parts, we'll point you to the right solution.
Very tight tolerances (under 0.2 mm)	FDM accuracy is about ±0.2 mm, not enough for some precision assemblies. For fits to the hundredth of a millimetre, CNC machining is the better choice.
Long exposure to outdoor UV	PLA degrades in the sun. PETG resists better but won't last forever outdoors.

Get a quote for your broken part

Send photos of your part through the contact form (photos and files welcome as attachments), on WhatsApp or by phone at +33 7 59 72 51 81, or by email at contact@toulouse3dprint.fr. You can write to us in English, and the quote is free.

The part is made in our Toulouse workshop at 64 boulevard Silvio Trentin. Collect it there, or we send it anywhere in France by Mondial Relay or Colissimo. We also ship abroad, by Mondial Relay or the carrier of your choice; the online checkout only takes French addresses, so contact us and we'll give you the shipping cost. Already have a 3D file? Upload it on our order page.

Frequently asked questions

Do I need to send the broken part?

Not necessarily. If you have the part, even broken, you can send it so we take exact measurements, or just send detailed photos with the key dimensions (length, width, thickness, hole diameters). If the part is too damaged, photos from several angles and a dimensioned sketch are enough in most cases.

How much does it cost to reproduce a part?

It depends on two things: CAD modelling (if you have no 3D file) and the printing itself. For a simple part such as a clip or cover, allow between €15 and €40. For a technical part needing precise modelling, the quote includes the design time. Send us photos for a free quote.

How long does it take to get my part?

It depends on how complex the modelling is and on the print time. We give you a precise timescale with the quote, and you can collect the part in Toulouse as soon as it's ready.

Does the 3D file belong to me?

By default, the 3D file we model remains the property of Toulouse3DPrint. You can buy the source file if you want to keep it for future orders or changes, which is worthwhile if you plan several copies.

Can a part be reproduced without the original?

Yes. We can model the part in CAD from detailed photos, dimensioned sketches, technical drawings or even a precise description. The more information you give (photos from every angle, measurements, how it's used), the closer the result.

Can you send the part outside France?

Yes. In France we use Mondial Relay or Colissimo. For another country, we ship by Mondial Relay or the carrier of your choice: contact us with your address and we'll give you the shipping cost.

Ready to start
your project?

A photo, a file or just an idea: send it over and we take care of the rest.

Describe my project Instant quote for 3D files