AriLea your the artist of this group. Have any ideas as to how Mark could make a grill insert with perhaps a laser cutter. I was thinking the superman pattern repeated as smaller and smaller shapes. Not sure what pattern would look nicest.
Well, now that you mention it, a 3d print is a likely best step for just the prototype. But a number of fabrication methods are available after that, including just cutting up an original gril. I think, this is actually a fairly low level challenge for Mark, with lots of options.
My opinion about the pattern, with such a small space, the borders will have a bigger influance than the actual grill. But as a guess I would think a honeycome pattern will look better than bars. It is a simple matter in this case to just draw up some examples, and the right one maybe obvious.
Here are some variations. And then deside, Chrome vs all Black, with or without a heavy frame border, thick and few, vs thin and many.
I think, very thin, many, honeycomb shapes, all black, no heavy frame, will look best with the most colors.
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Thick bars makes the grill ordimental and stand out as the primary feature, thinner makes it recede into the face leaving other shapes in the front end to stand out. So the real question is, do you like the current face, and do you wish to modify the overall look with your grill? And how do you wish to match it in the lower wide area? I think again, very thin, many, honeycomb shapes, all black, no heavy frame.
Many cars, currently are doing the same. Also the plain honeycomb will look pretty good if a logo is added to the center.