3D Printing 1:4 Scale Borrani Wire Wheel
I started the build with the wheels, but the tires proved more difficult than expected. The flexible TPU filament I initially tested was not suitable—the combination of tire diameter, sidewall geometry, and softness in the material led to poor dimensional stability and surface finish. My intent was to replicate the classic Borrani wire-spoke design using 3D metal printing, and those components came out beautifully, capturing the intricate spoke detail and authentic profile. However, for the tire and hub assembly I shifted to a split-wheel solution, produced on the Bambu Lab X1 Carbon in Black PLA Matte.
This approach provided the necessary structural rigidity and surface quality, while still allowing the wheel and tire components to interlock accurately for assembly and display. Eventually, I might figure out how to print soft rubber tire but for now, this method seems to have worked out just fine!