3D-Printed Fog Light Housings - Hyundai Kona N

The Hyundai Kona N is one of many cars these days that came without a factory option for fog lights. As I spend half the year commuting through dense fog, this naturally presented a slight issue! I had a set of Diode Dynamics SS3 Sport fog lights saved from a previous vehicle, so I decided to make them fit the Kona N. I used a free iPhone app called Kiri Engine to capture 3D scans of the fog light and the Kona's front lower grille, and imported them into another free CAD utility, OnShape. There, I used the 3D mesh as a reference point and designed a shroud and mounting bracket that enables my Diode Dynamics lights to mount right up to my Kona's lower grille! First, I 3D printed a set of hole saw guides I designed alongside the shroud, which allowed me to cut a precisely-located hole to ensure the parts can be installed exactly where they were designed to be. I then 3D-printed the parts out of solid ASA, a material known for its toughness and resistance to UV exposure. The final step... cut up my car's grille!

Finally, the modified grille/light pod assembly could be installed back onto the vehicle. The results have been phenomenal - I achieved my goal of making the lights look as factory-made as possible, and was able to re-use an existing set of lights instead of purchasing new ones. The car's light output is significantly improved, and thanks to careful measurement and aiming, the beam pattern does not produce any glare towards oncoming traffic. Mission accomplished!

This was a much more involved project than this write-up lets on - but after months of troubleshooting equipment/CAD, getting measurements right, and painstakingly putting everything together by hand, the results were extremely gratifying!

I hope to soon make the CAD files available for anyone to download and print on their own. Links will be pasted below once this is achieved! Thanks for reading!