Obsolete Kawasaki Airbox Connector

This airbox-to-carburettor connector is shared by the Kawasaki KE125, KD125 and KS125. When the original deteriorated and a replacement was unavailable, Protomotus developed a new component in flexible TPU. CAD modelling and a rigid prototype established the geometry and fit, followed by iterative support development to manufacture the complex shape and remove supports cleanly. The gallery follows the process from digital model to completed replacement.

1975 Kawasaki KD125 shown for model context. The airbox connector is shared by the KE125, KD125 and KS125; this reference image does not show the project motorcycle.
CAD model developed to reproduce the unavailable airbox-to-carburettor connector.
Early rigid prototype compared with the deteriorated original component, used to verify dimensions and fit.
Iterative development of the support-material strategy for complex unsupported geometry, balancing reliable formation, clean removal and protection of the flexible component.
The replacement connector being manufactured in flexible TPU with carefully implemented support structures.
The deteriorated original component alongside the completed functional TPU replacement.
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