Preserving Victorian Engineering Through Digital Manufacturing

The iconic “Penny Farthing” is one of the most recognisable bicycles in history, instantly identifiable by its oversized front wheel and much smaller rear wheel. However, despite the name becoming widely associated with the design, “Penny Farthing” was never actually its original name.

When these machines first appeared during the late 19th century, they were simply referred to as bicycles, and later became known more formally as the ordinary bicycle. The now-famous nickname only emerged later, inspired by the visual similarity between the large and small wheels and the size difference between the old British penny and farthing coins.

This particular example was originally built in 1879 by Humber, Marriott & Cooper, a company that would later become well known within British engineering and automotive history under the Humber name. Like many surviving examples of Victorian engineering, the bicycle represents not only an important stage in transport history but also a remarkable example of early mechanical design and manufacturing.

Over time, however, many original components on historic vehicles and machinery inevitably deteriorate through age, wear, and use. In this case, the original pedal foot rubbers had become worn and required replacement in order to preserve both the functionality and authenticity of the bicycle. Unfortunately, sourcing original replacement parts for machines of this age is rarely straightforward, with many components no longer commercially available in any form.

To help recreate the missing parts, BritForge3D used modern digital manufacturing techniques to produce accurate replacement pedal rubbers while still retaining the appearance and character of the originals. The process began by carefully assessing and measuring the surviving components so that replacement versions could be modelled accurately using CAD software.

The replacement pedal rubbers were then recreated in Fusion 360, allowing detailed 3D models to be produced and refined before manufacturing began. Using CAD modelling software made it possible to recreate the shape, dimensions, and mounting features of the original parts while ensuring the final replacements would fit correctly once installed onto the bicycle.

Process, Material Selection, Final Thoughts

The material selection also played an important role within the project. The replacement parts were produced using TPU, a flexible and durable 3D printing material commonly used where impact resistance and elasticity are required. Unlike rigid plastics, TPU provides a rubber-like flexibility, making it particularly well suited for components such as pedal rubbers that experience repeated contact and movement during use.

Using 3D printing technology allowed the replacement components to be manufactured efficiently without requiring expensive tooling or mould production. Traditional manufacturing methods for low-volume heritage parts can often be prohibitively expensive, particularly when only a small number of components are required. By contrast, additive manufacturing provides a practical and cost-effective solution for reproducing rare or obsolete parts in limited quantities.

Projects such as this highlight how modern 3D scanning, CAD modelling, and additive manufacturing technologies are increasingly being used within the heritage and restoration sectors. In many cases, these tools provide an opportunity to recreate parts that would otherwise be extremely difficult to source, helping preserve historically important machinery and vehicles for future generations.

The Penny Farthing itself also represents an important stage in the evolution of bicycle engineering. While visually striking, the design had significant limitations, particularly in terms of balance, safety, and gearing. Riders sat high above the ground, and because the pedals were connected directly to the large front wheel, stopping suddenly or striking uneven ground could easily result in serious accidents.

By the late 1880s, British inventor James Starley introduced the chain-driven rear-wheel bicycle, a development that would eventually lead to the modern “safety bicycle” design still used today. By separating pedal speed from wheel size through the use of chain gearing, bicycles could use smaller wheels while remaining faster, safer, and easier to ride. This innovation quickly made the ordinary bicycle obsolete, despite its iconic appearance and popularity during the Victorian era.

Today, surviving Penny Farthings remain an important reminder of early engineering innovation and the rapid development of personal transport during the Industrial Revolution. Restoring and preserving these machines is not simply about maintaining historic objects. It is also about preserving the craftsmanship, mechanical thinking, and engineering heritage that shaped modern transportation.

Projects such as this demonstrate how modern manufacturing technologies can now work alongside traditional restoration methods to help preserve engineering history. By combining CAD modelling, TPU 3D printing, and careful reproduction techniques, it becomes possible to recreate missing or worn components while still respecting the originality and character of the historic machine itself.

Preserving Rare Classic Car Parts with Modern Technology

The MGB GT V8 remains one of the most iconic British sports cars of the 1970s. Manufactured between 1973 and 1976, only around 2,600 vehicles were originally produced, with estimates suggesting that approximately 1,000 examples still survive today. As with many low-production classic vehicles, sourcing original replacement parts is becoming increasingly difficult, particularly for specialist components that were often removed, damaged, or lost during earlier repairs and restorations.

One such component is the original exhaust shroud assembly. Although relatively small, these shrouds played an important role in helping manage heat and airflow around the exhaust system.

For collectors and enthusiasts restoring their vehicles back to factory specification, retaining these details is an important part of preserving the originality and character of the car. Unfortunately, very few original shrouds are still available, making accurate reproduction parts increasingly desirable within the classic car restoration community.

3D Scanning Original MGB GT V8 Parts

To help reproduce these rare exhaust shrouds, BritForge3D began by digitally scanning an original set of components. This process allowed the shape, dimensions, and mounting features of the original parts to be captured accurately and converted into detailed digital 3D models.

Using 3D scanning technology meant the original parts could effectively be reverse engineered without relying on original factory drawings or tooling, which are often no longer available for classic vehicles of this age. Once the scan data had been processed, detailed CAD models were created and refined to ensure the reproduced parts remained faithful to the originals while correcting inconsistencies caused by age, wear, and distortion.

Creating PETG Prototype Parts for Test Fitting

Before moving to final production, prototype versions of the exhaust shrouds were produced in PETG using FDM 3D printing. These prototype parts allowed the client to physically test fit the shrouds to the vehicle and confirm alignment, mounting points, and overall fitment before any metal manufacturing work began.

This stage proved extremely valuable during development. By using PETG prototypes first, adjustments and refinements could be made quickly and cost-effectively before committing to the considerably more expensive stainless steel manufacturing process. The prototypes acted as functional test pieces, helping reduce both risk and development costs during the project.

PETG was chosen for the prototype stage because it offers good dimensional stability and durability while still being relatively quick and economical to produce using standard 3D printing methods. Although the PETG versions were never intended as final production parts, they provided an efficient way of validating the design before moving to metal production.

The Challenges of Stainless Steel 3D Printing

The final intention was to manufacture the completed exhaust shrouds in stainless steel using industrial metal 3D printing technology. However, sourcing a suitable supplier capable of producing stainless steel 3D printed parts proved to be one of the more challenging aspects of the project.

While plastic 3D printing has become widely accessible in recent years, stainless steel additive manufacturing remains a highly specialised process requiring industrial-grade machinery, controlled production environments, and extensive post-processing capabilities. Unlike conventional desktop 3D printers that use plastic filament, metal additive manufacturing systems use fine stainless steel powders and high-powered laser systems to build parts layer by layer.

This process is significantly more complex and expensive than standard polymer printing, with additional considerations such as thermal distortion, support structures, surface finishing, and material shrinkage all needing to be carefully managed throughout production.

Because of these complexities, BritForge3D chose to work with a specialist third-party metal additive manufacturing company for the final stainless steel production stage. Using a dedicated metal printing supplier ensured the finished parts could be manufactured accurately while maintaining the appearance and functionality of the original components.

Modern Manufacturing in Classic Car Restoration

Projects such as this demonstrate how modern manufacturing technologies are helping preserve rare and obsolete classic car parts that would otherwise be extremely difficult, or even impossible, to obtain. Traditional manufacturing methods would often require expensive tooling and specialist fabrication work, making small production runs economically unrealistic for niche restoration projects.

By combining 3D scanning, CAD modelling, PETG prototyping, and stainless steel 3D printing, it is now possible to reproduce rare automotive components with a high level of accuracy while significantly reducing development time and cost.

For classic car enthusiasts and restorers, these technologies are becoming increasingly valuable tools in preserving originality and keeping rare vehicles such as the MGB GT V8 on the road for future generations.

As additive manufacturing technologies continue to evolve, reverse engineering workflows such as this are becoming an increasingly valuable tool for restorers, collectors, and engineering specialists working to preserve historic vehicles and low-production automotive designs.