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Manufacturing a Headlight Adjustment Gearbox for the Ferrari 360 Modena

In July 2024, at the request of Provile Inc., we manufactured a replacement headlight adjustment gearbox for the Ferrari 360 Modena, a component known for its fragility. This part is not available individually—if it breaks, the entire headlight assembly must be replaced, costing approximately ¥720,000 (per side). Used parts are also unreliable and difficult to refurbish.

In this project, we restored and modeled a damaged unit that had about 30% of its structure missing. While inferring the original design intent, we made structural improvements and redesigned the part. We believe the new gearbox offers superior heat resistance, chemical resistance, and strength compared to the original. There is still room for improvement, and if this version fails in the future, we plan to ignore the original design entirely and develop a new gearbox from scratch.

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