3D scanning & printing

[Austexican]

Guys, I know you like to show off your welding, shaping, fabrication in metal and fiberglass, and other shop skills. You may be missing out on some opportunities for one-off custom work. I've read that some in the community are using laser cutting technology, but I have yet to discover in this forum any reference to 3D scanning and printing used in developing prototype or custom work. As for my own experience, I got a D-minus in middle school shop class because my father remembered that his shop teacher was missing a finger. Dad refused to sign the form that gave parental permission for me to operate power tools! However, after two years of studying mechanical engineering at university and flunking most of the math courses, I was put on scholastic probation. That gave me the opportunity to take up full time employment on the graveyard shift at WKM Valve Division in Missouri City, Texas where I machined small valve gate assemblies for installation on the Alaska pipeline. My ability to read engineering drawings, perform set-ups, maintain tolerances, and achieve production quotas led to my rapid promotion to sole operator of the small (1 1/4 to 4 inch conduit) valve gate machining and assembly station. Production runs could be in the dozens or in the thousands. Intake was raw castings in various steel alloys, stainless steel, or bronze. I operated two broaches (one had saw blades over twelve feet long), counter sinks, drills, hones, taps (left-hand), turret lathes, etc.

The money I saved financed a BA in liberal arts (fastest way to graduation) and an MA in international studies. I've been working in the field of information technology and diplomacy since 1980. In my spare time I have also constructed some highly finished hunting and camp knives and done some custom gunsmith work. The point is that all of my experience is in stock removal to achieve a desired application and custom fitting. However, my information technology experience informs me that much custom work and prototyping can be achieved in 3D printing technology which is cost effective for the individual.

What do you folks think about it?

[skullandbones]

First time I've heard of "cost effective for the individual" and 3D printing in the same conversation. I know NASA is developing a 3D printer for the crew of the first Mars mission to take along for creating parts and tools as the commute is brutal!!! Love to hear more about it.

Thanks,

WEK.

[Mike N]

Google Rep Rap. If you know someone with a Rep Rap machine they can make you most of the pieces you need to build your own. There are some very economical 3D printing set ups out there.

It won't be long before material removal processes (machining) are virtually completely replaced with material 'placement' processes. F1 teams use 3D printing extensively for smaller aero and wind tunnel test parts and are starting to use 3D metal processes (laser sintering) for key structural pieces. One unique thing about 3D printing is that you can create hollow parts very easily saving a lot of weight.

[Austexican]

I was thinking about 3D printing as a way to build headlight surrounds for my Type 65 Coupe. The complex curves are a challenge. The early Jaguar XKE's had chrome surrounds as in the picture. How did Jaguar do it? Was it perhaps a brass casting that was polished and chromed? Has anybody fabricated metal surrounds for the headlight covers?

[WIS89]

Here's a machine on Amazon. It's a stretch for some, but considering this is pretty much bleeding-edge technology, it is not unreasonable. The future for these machines is unlimited, and should change much of how things are manufactured today. Exciting stuff!

http://www.amazon.com/RepRap-Mendel-Iteration-Complete-Printer/dp/B00DMRR4BG

I like the idea of needing a part, getting sent a CAD/CAM drawing, and making your own in short order. Not just for our cars, but any part for an appliance in our homes, or almost anything we can think up. This is a truly disruptive technology, and could prove invaluable.

Regards,

Steve

[skullandbones]

I have checked out the Rep Rap websites as suggested by Mike. However, I don't see metal 3D out there. Using plastics as a substrate for the 3D is one thing but metal formation is a whole different ball game. I was reading about one young guy working with a large university on metal 3D. He was experimenting with new alloys of metal that would become the right molten consistency and form in the process like the PLS/ABS plastic counterparts. If that has progressed where it is trickling down to the average home user, I can't find it. I thought the discussion was about metal components. If that's the case, I don't see that process replacing metal machining and metal removal for some time due to the expense. Thanks, WEK

[Austexican]

If you have the dimensions of the part you designed in CAD format, you could take them to a facility that has a printer that produces metal parts. You wouldn't have to purchase the printer. Another possibility is to produce the part in plastic and use the plastic to form a sand mold for casting the metal part.

[wolfhound]

It would sure be nice if you have access to one.

[Mike N]

I have checked out the Rep Rap websites as suggested by Mike. However, I don't see metal 3D out there.

Check this out http://www.youtube.com/watch?v=cRE-PzI6uZA This is not feasible as a 'do it at home' (yet) and it's not cheap but it will come down in cost as use increases. There are many other videos and companies out there if you want to take the time to search.

[Austexican]

Good find. One of the other videos on the same page shows a really complex shape created for a Formula 1 heat exchanger. I can't really imagine how it might have been manufactured with casting or material removal (machining) technologies.

http://www.youtube.com/watch?v=zApmGFDA6ow

[tirod]

If it can be 3D printed, it can likely be fabricated by a clever engineer and die maker. We are a long way from making 3D cost effective for the average garage builder - not only the actual device needs to be built or acquired, the code has to be generated to make that part, and it has to do it perfectly. I've worked in a CNC shop and heard when code goes wrong, and seen when a Turret Press is made inoperable by the programmer. At least a 3D isn't as affected by catastrophic inaccuracy and won't likely self destruct. It will just put out another junk part for the First Article inspector to fail, and the programmer to go back and make more changes in code.

That will be the one and same person - the kit builder. I see the kit as the end product, not the process. There is also enough pressure to divert the finance stream away from the car and into tooling - ask the guys who decide to paint their own body. It takes about $2000 for the compressor, guns, finishing materials, and paint. All that gets expensed on one job - not a continuing business that could amortize the cost over years of use.

That's where 3D doesn't work yet for the home builder. He can explore sand casting brass, adjusting the forms, polishing the results and having them chromed for a lot less than the cost of learning a new career in writing code, plus the cost of the machine and materials to make the part. And, it doesn't guarantee the result, how many do you have to make to get the final ones right? Just bend the brass with a torch and try fit again seems simpler. Hand crafting parts can be and is faster and cheaper than attempting a process that is geared for mass production. It's no different than inventing the world's best water pump by drop forging the body of it. Extremely expensive method for one item, dirt cheap if it's spread out over a years production - like AR uppers and lowers. You get your money out of the dies making thousands.

I'm not seeing 3D as a viable technique for many, it's getting a lot of press, but the guys who program it aren't the ones publishing the articles. It fills exactly the niche industry has for it - rapid prototyping. Not custom or mass production of finalized parts.