The West Midlands Police force in the United Kingdom recently began to introduce 3D printing into its fleet workshops after one technician’s home project revealed a faster and more flexible way to produce custom vehicle components. The move is already helping the force reduce its repair times, cut costs, and return operational vehicles to the road more quickly than ever before.
The idea came from Daniel Starns, a Fleet Services vehicle technician who is tasked with converting commercial vehicles into fully equipped police cars. These conversions often require extensive interior modifications to the car, including new communications systems, computers, and other specialist hardware. Previously, technicians would remove and reshape the existing panels, fabricate new metal mounts, and wait for replacement parts when original components were damaged. While the work was effective, it was often slow and labour-intensive.
An example of a 3D printed part for emergency lights on the radiator grille of a new cruiser. (Credit: West Midlands Police)
While experimenting on his personal 3D printer, Starns realised that he could replicate and customise many of the parts the force had to routinely adjust. He first began to test this new method using measurements for the interior panels and fittings. He would produce prototype pieces in plastic instead of reshaping the original components. The early prints helped to provide a precise match and offered a more consistent finish than manual fabrication.
Starns brought the concept to Acting Fleet Manager Kelvin Bevan, who immediately recognised the potential. Fleet Services soon acquired a 3D printer for in-house production and began manufacturing parts for stock to support both internal workshops and external repair partners. These printed components now replace brackets, interior trims, light mounts and other small fittings that once required time-consuming custom engineering.
Another example where 3D printing was used within the gear stick panel to include the activation buttons for police sirens and lights. (Credit: West Midlands Police)
The adoption of 3D printing has significantly reduced build and repair times, allowed the team to create exact replicas of manufacturer designs, and lowered overall material and labour costs. It has also improved the efficiency of vehicle conversions by eliminating delays associated with ordering original parts, especially for cars that have sustained damage or require unique adaptations.
Chief Constable Craig Guildford praised the initiative after reviewing sample designs created by Starns and Bevan. He described the project as an example of practical innovation that enhances the force’s operational readiness. Faster access to replacement components means fleet vehicles spend less time in workshops and more time supporting frontline policing.
West Midlands Police expects to expand its use of 3D printing as Fleet Services continues refining designs and exploring new applications. What began as a personal experiment has quickly become a valuable tool for improving the speed and quality of police vehicle maintenance and customisation.
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*All Photo Credits: West Midlands Police, United Kingdom