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Re: [PSUBS-MAILIST] Ready to print



Who needs draft? Melt the master out and do investment casting.

Best,
Marc

On 2/14/2012 3:16 AM, Sean T. Stevenson wrote:
One thing that nobody has mentioned yet is to look beyond using the
available plastic materials to simply produce finished parts.  3D
printed plastic solids actually make ideal positive molds for sand-cast
aluminum or steel parts, and can save you a significant amount of money
on castings when you avoid having to involve a skilled pattern maker -
particularly for complicated geometries, compound curves, etc.
Designing for casting is not difficult - just a few key considerations
such as adding draft (slight taper to facilitate removal from mold),
avoiding cooling / shrinkage problems by avoiding abrupt thermal mass
changes in geometry, and maintaining reasonable minimum wall
thicknesses.  After casting, you can either finish mechanically, or as a
colleague of mine does regularly, trim the worst by hand, sandblast to
even out the rest, then spray with polyurethane or "tool dip".

As far as suggestions for finished plastic 3D printed parts, I might
look at things in non-critical service, such as fairings, aesthetic
trims, console bezels, etc.

-Sean

On 2012-02-12 18:10, JimToddPsub@aol.com wrote:
Hi, Alec,
I checked Wikipedia for the different types of 3D printers and learned
more than I have the capacity to absorb at this point.  ABS might be a
good alternative to metal for actuator housings.  I'm sure I'll be
considering the question for a number of components.
By the way, last week I went through your Snoopy250 and Snoopy Updates
postings on the Psubs website.  Picked up some good ideas and
suggestions.  Thanks for taking the time to take all those pics and
post your comments.
Take care,
Jim
In a message dated 2/12/2012 7:33:16 P.M. Central Standard Time,
Alec.Smyth@compuware.com writes:

    Hi Jim,

    There are a variety of materials available, but the two most
    common are ABS and PLA. For kids toys and such I'm using PLA
    because it's biodegradable. If you're going to be melting plastic
    inside the house for hours on end, it strikes me as preferable to
    use something that is derived from plants and doesn't smell bad.
    For sub parts, though, I'd use ABS because it's stronger. I don't
    have specs handy, but it's the same material Legos are made of, so
    should be relatively tough.

    There is no manufacturer for the machine, I made it from parts
    that I collected from a variety of sources - mainly eBay. As for
    accuracy, it's  highly variable and depends, from what I've seen,
    much more on the experience of the person calibrating than the
    inherent capabilities of the machine. I'm a rank beginner, so I
    don't expect to make anything superb, but the quality I'm getting
    at this point is sufficient that I would not feel bad putting
    parts on the sub, presentation-wise. I'd say it's functional and
    not embarrasing, but certainly not yet the finish you'd expect
    from a mass produced, molded item.

    If you want to read a little about this stuff, do an online search
    for "reprap", which is a collaborative, online project to develop
    these machines, or for "Prusa Mendel", which is the particular
    sort of printer I built, a model developed by the Reprap project.
    More generally, common terms for this topic are "additive
    manufacturing" and "desktop manufacturing".


    Best,

    Alec


    On Feb 12, 2012, at 8:02 PM, "JimToddPsub@aol.com
    <mailto:JimToddPsub@aol.com>" <JimToddPsub@aol.com
    <mailto:JimToddPsub@aol.com>> wrote:

    Hi, Alec,
    I don't have any need at the moment, however I'd like to hear
    more about the material's properties and characteristics such as
    torsion strength, etc.  Are there different formulations of
    plastic material for use with your 3D printer at this time?
    How precisely can it produce an item?  Is there general info
    available online at the manufacturer's website?
    Thanks for the offer.  I'll need to take a closer look at 3D
    printing in general versus machine work when I get to that point.
    Best regards,
    Jim T.
    In a message dated 2/12/2012 4:32:22 P.M. Central Standard Time,
    Alec.Smyth@compuware.com <mailto:Alec.Smyth@compuware.com> writes:

        Hi everyone,

        I’d mentioned a few weeks ago I was working on a3D printer.
        Itisnowcalibratedandworking really nicely.Ihave to say, it’s
        a neat concept tojusthit a button and
        watchthingsmaterializewithout further intervention.Now the
        question is what toprint.There are twomainlimitations:

        - Partsmustfitona build areameasuring6.75”x 6.75”and4”tall,
        orthey have to be assembled from parts that fit into that space.

        - Overhangs have to begradual. To illustrate, consider
        printing amodel of ahouse.You wouldhave to print the roof as
        a separate part and then attach it to the walls,otherwise
        when the nozzle reached the height of the eaves it could not
        print thembecause they would beunsupported.

        I know there are some terrific CAD artists in the house, and
        I’d like to invite you to undertakethe design ofprintablesub
        componentson an“open source”basis. I’d be quite happy to
        printthoseparts for just the cost of the plastic,if we can
        come up with some commonsub components. Wecouldmake parts
        assimpleashandles forKittredge stylehatchdogs, ormaybeattempt
        an UWlight or a scrubber.Maybe we can even start a repository
        for the files.

        Any takers?


        Thanks,

        Alec


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