Audi TT Custom Intake System
3D scanning, design, prototyping and functional fabrication
Project Overview
Project: Audi TT Custom Intake System
Service: Automotive Design and Prototyping
Application: Functional Engine Bay Component
Vehicle: 2016 Audi TT S-Line Quattro
Process: 3D scanning, CAD design, Prototyping, Fitment testing and Final Fabrication
Manufacturing: Additive manufacturing with automotive-grade hardware
From Idea to Design
The goal was to develop a custom intake system that improved the driving experience while fitting cleanly within the tight packaging constraints of the Audi TT engine bay.
A 3D scan of the engine bay provided the foundation for the design, allowing the intake path and surrounding components to be developed around the vehicle’s existing geometry.
Digital Development
The scanned engine bay was converted into a digital reference environment, allowing the intake system to be designed around nearby factory components before physical parts were produced.
This reduced trial-and-error and helped identify packaging, clearance and routing constraints early in the development process.
Prototyping & Fitment
Early prototypes were produced to test geometry, clearances, airflow routing and fitment inside the engine bay.
Lower-cost prototype materials were used during development so multiple design iterations could be evaluated before committing to the final build.
Final Fabrication
Once the design was validated, the final components were manufactured and assembled with attention to fit, durability, and integration with the surrounding factory hardware.
Each part was produced specifically for the vehicle and assembled into the completed intake system.
The Finished System
The completed intake system integrates cleanly into the Audi TT engine bay and demonstrates the full development process from 3D scanning and CAD design through prototyping, fitment and final fabrication.
Driven by curiosity and built on purpose, this is where bold thinking meets thoughtful execution. Let’s create something meaningful together.