3 D printing of distributor cap

[MBfreak]

The MB W140 serie 90-94 ( V8s 4-6 l) has one 4 pole distributor cap on the front of each cylinder head, directly driven by the camshaft.
Electronic ignition module, spark can kill an elephant!
Unfortunately it also kills the distributor cap. Typical lifetime is 3000 miles. And the cost around $ 175/ea.

Has anybody tried 3 D printing a distributor cap? If so, what material?
Will add picture.

Best regards.
Ola

 

[AirMech#406]

A quick search on Thingiverse reveals several models, so people have done it.

I would think at the very least either ABS/ASA. Although I would would feel far better using either nylon or poly carbonate. 3DXTECH has a whole line of ESD safe filaments which I imagine would be well suited for that kind of application.

The main considerations are
1) heat
2) electrical resistance

So your focus would be finding a filament which addresses both of those issues

 

[WAID]

A quick search on Thingiverse reveals several models, so people have done it.

I would think at the very least either ABS/ASA. Although I would would feel far better using either nylon or poly carbonate. 3DXTECH has a whole line of ESD safe filaments which I imagine would be well suited for that kind of application.

The main considerations are
1) heat
2) electrical resistance

So your focus would be finding a filament which addresses both of those issues

Ozone resistance may also be an important consideration

 

[Firebrick43]

A quick search on Thingiverse reveals several models, so people have done it.

I would think at the very least either ABS/ASA. Although I would would feel far better using either nylon or poly carbonate. 3DXTECH has a whole line of ESD safe filaments which I imagine would be well suited for that kind of application.

The main considerations are
1) heat
2) electrical resistance

So your focus would be finding a filament which addresses both of those issues

And/asa has pretty lousy heat resistant and arc resistance values.

Nylon is better.

Straight POM has the best arc resistance of any of the printable plastic.

You don’t want the impact or low friction variants.

Hope you have a heated chamber that required for anything useful

Now as for one caps lasting only 3000 miles, something is wrong. Is the camshaft seals misting causing carbon tracking? Plug gap to large cussing excessive voltage?

A road engine shouldn’t require that high of voltage to deal with it (relatively)low compression

 

[MBfreak]

Thanks for the very helpful answers.
Will find out if we can use POM or nylon.

The tracking on the inside surface of the cap is probably caused by particles built up by residue from the metal parts during arcing.
And an overzealous peak voltage. There is no oil residue at all. The rotor shaft has a slinger before it enters the distributor assembly.

Ola

 

[AirMech#406]

Thanks for the very helpful answers.
Will find out if we can use POM or nylon.

The tracking on the inside surface of the cap is probably caused by particles built up by residue from the metal parts during arcing.
And an overzealous peak voltage. There is no oil residue at all. The rotor shaft has a slinger before it enters the distributor assembly.

Ola

What is the brand/model of your 3d printer?

 

[drtyler]

Why does this failure happen? Certainly MB wasn't replacing caps every 3000 miles when the cars were new. What changed?

The MB W140 serie 90-94 ( V8s 4-6 l) has one 4 pole distributor cap on the front of each cylinder head, directly driven by the camshaft.
Electronic ignition module, spark can kill an elephant!
Unfortunately it also kills the distributor cap. Typical lifetime is 3000 miles. And the cost around $ 175/ea.

Has anybody tried 3 D printing a distributor cap? If so, what material?
Will add picture.

Best regards.
Ola

 

[MBfreak]

drtyler
The 6 and 8 cyl MBs from 85 to 94 were all afflicted by the same problem.
Poor material choice. Bosch experiment. Tracking from center to output pins.
MB has had several problems during the period
Wiring looms that broke down. 420 SL engine bay loom costed appr $1200. No warranty. Poor material. like uncooked spagetti.
A new paint procedure that was totally useless. Cars rusted out, everywhere.

Cake eater product design

Ola