As a personal project, I designed and fabricated a custom Porsche logo wall piece, combining precision machining, welding, and finishing techniques. Inspired by my passion for precision-manufactured sports cars like Porsche, I wanted to create a piece that reflects what the brand represents—speed, excellence, and engineering precision. Using SolidWorks for CAD modeling, I planned a multi-layer design featuring a metal front plate and a stained wood backplate. The process involved waterjet cutting, TIG welding, sandblasting, grinding, and painting to achieve a high-quality finish. This project showcases my CAD skills, hands-on manufacturing experience, and commitment to craftsmanship in bringing a concept to life.
Design Process
CAD Design & Planning:
I began the project by designing the Porsche logo in SolidWorks, ensuring accurate proportions and alignment. I imported a .png file of the Porsche logo into SolidWorks, traced it as a sketch, extruded the following positive displacement parts, and then exported as a .dxf file for the Waterjet machining process.
Material Selection:
Front Plate 16gauge galvanized steel, chosen for its durability and clean finish.
Waterjet Cutting:
The metal front plate was cut using the Cal Poly Mustang '60 Student Machine Shop waterjet machine, providing precise, clean edges for the intricate Porsche emblem details (+/-0.030 tolerance).
Using my hand for reference to show the scale of all the parts once they were extracted from the glavanized steel stock and cut out from the waterjet tabs.
(Above) TIG Welding & Assembly:
I used TIG welding to add a 2.00'' steel tab to the back of each of the components, ensuring structural integrity. Any excess material or rough edges were ground down using an angle grinder for a smooth surface.
Surface Preparation (Sandblasting & Grinding):
Following the welding process, the metal surface was sandblasted to remove oxidation and imperfections from the welding and waterjet processes and to create a uniform texture. Additional grinding and smoothing ensured sharp definition in lettering and emblem details.
Woodwork:
I laminated multiple pieces of poplar to create the wooden backplate, ensuring sufficient thickness and structural integrity. Once bonded, I planed the surface to achieve a uniform, smooth finish. The wood was then cut to match the metal offset profile using a bandsaw, ensuring precise alignment. To refine the edges and enhance visual cleanliness, I used a table router to create a smooth, consistent perimeter, giving the piece a polished, professional appearance. Additionally, I primed and painted the glavanized steel plate white.
Assembling the Final Piece:
The painted metal front plate is mounted onto the stained poplar backplate using spacers, creating a floating effect for added depth and contrast. The combination of precision machining and woodworking enhances the visual impact of the Porsche emblem.
Mounting & Final Presentation:
The finished piece was securely mounted on the wall using hidden fasteners, maintaining a clean aesthetic. The final result is a custom, handcrafted Porsche emblem that combines precision machining with artistic craftsmanship.