What every home machinist needs

[X1 Mike]

Technology, not so bad.

Note the price he says, less than $3 k and made in the U.S.A. to boot.



http://widgets.nbc.com/o/47f1317f10...fe70d4555df05a/9e46bd46/-cpid/ba4377d3bfd6c81

 

[35mastr]

That is the machine to have for those parts that are no longer availible.

Thanks for the link. Nice to know that that this stuff is actually availible.

 

[Paumanok]

Whoa - THAT is insane Incredibly awesome, I can't believe the adjustable wrench that was printed came out readily funtional, as well as the steam piston Technology blows my mind.....when prices come down in like ten years - I want one

Extra thanks for that link!! And I love Leno's addiciton to awesome cars/machines old and new - he is a great supporter and proponent of American industry/MFG.

 

[X1 Mike]

I have to agree my jaw just about dropped when I seen the wrench working.

 

[kbs2244]

I am a little confused.
These are 2 different machines by 2 different companies?

The “printer” is amazing.
But the “scanner” can give you points that can be transferred to a CNC mill if you don’t have the printer for a test step?

 

[Jeepguy]

uh, that looks like a pirate parters new best friend. haha i can see all of the little asain shops making even more money off of pirate parts.

 

[Garage_Mahal]

They are already doing that in droves.

 

[bbshriver]

I can't view that video at work, but based on the discussions here I can tell it is one I have seen. This technology has been aroud for a while as "rapid prototyping" I work in a vehicle test lab where we have this kind of stuff. Thing is back in the day the "3D printer" cost about $100k, and the resin used is hundreds of dollars a gallon I think. The new 3D printer at ~$15k is starting to get in the feasible realm if you have a real use for it. The 3D scanner for ~$3k is downright cheap! There is software to convert to correct format for a variety of applications, for instance you could convert to e-machineshop type file and send off for parts.

I have been seriously considering the scanner for aid in designing aftermarket motorcycle parts, via eMachineShop.

https://www.nextengine.com/indexSecure.htm

http://www.dimensionprinting.com/

I believe these are the 2 Jay leno references.

 

[KenB]

And prices are coming down all the time. Imagine, a machine that can replicate itself! Here is a hobbyist "open source" effort: http://reprap.org/bin/view/Main/WebHome.


Ken

 

[Bolster]

Wouldn't they have had a copy (they'd have to machine it to clean up obviously) if they'd skipped the whole high-tech plastic intermediary process, and just cast from the broken original? It's cool, but why was the intermediary step of a plastic copy necessary?

 

[X1 Mike]

I can't view that video at work, but based on the discussions here I can tell it is one I have seen. This technology has been aroud for a while as "rapid prototyping" I work in a vehicle test lab where we have this kind of stuff. Thing is back in the day the "3D printer" cost about $100k, and the resin used is hundreds of dollars a gallon I think. The new 3D printer at ~$15k is starting to get in the feasible realm if you have a real use for it. The 3D scanner for ~$3k is downright cheap! There is software to convert to correct format for a variety of applications, for instance you could convert to e-machineshop type file and send off for parts.

I have been seriously considering the scanner for aid in designing aftermarket motorcycle parts, via eMachineShop.

https://www.nextengine.com/indexSecure.htm

http://www.dimensionprinting.com/

I believe these are the 2 Jay leno references.

Yes I am aware the technology has been around for a while, the point is now it is affordable. This is a good opportunity for start up companies to compete with the big boys.

 

[Stuey]

I cannot watch the video right now, but I received a sample of a rapid prototyped wrench about 3 1/2 - 4 yrs ago. It's nothing new, just cheaper and more capable. But is it really affordable yet?

A year ago I was at a manufacturing convention, and a solid works rep was showing off a few rapid printed prototypes. Very cool stuff.

I don't think this type of tech will make it into DIYers' homes anytime soon, but you never know. Maybe one day there will be open source software running affordable machines.

These days small CNC tech is starting to make its way into garage and basement workshops. Who knows what 10 more years will bring.

 

[jacob]

Wouldn't they have had a copy (they'd have to machine it to clean up obviously) if they'd skipped the whole high-tech plastic intermediary process, and just cast from the broken original? It's cool, but why was the intermediary step of a plastic copy necessary?

Yes, they could have cast it from the original.

What this technology allows them to do is to scan the original and then build a replica in a CNC. You can also send the digital image to the manufacturer, who can "print" it, and cast it. Then they can ship it to you, from anywhere in the world. You don't need to ship the old part, just send the digital image.

I think they were just trying to show all the things that can be done with this technology.

 

[The Rusty Gear]

Wouldn't they have had a copy (they'd have to machine it to clean up obviously) if they'd skipped the whole high-tech plastic intermediary process, and just cast from the broken original? It's cool, but why was the intermediary step of a plastic copy necessary?

Shrink. The replacement part would be 3-4% smaller than broken original.

 

[rsanter]

not sure I need one but I sure want one..


I was trying to get the last company I worked for to buy those but couldnt get it to happen.
the scanner is a deal, not as good as the expensive ones but good enough for most work.
the 3D printer is big bucks to buy and the material is bucks as you consume it.

there is another type of 3D printer that uses a liquid that is solidified by a laser and will give a really nice finish. some of the auto companies will use them to make prototype intakes because they are good enough to flow test and then test run on a dyno a few times

yes another 3D printer company makes one that applies an activator to a powder material. the nice thing about their system is the the activator you use will determine the material type you get out. one activator will make a rigid part and another can make a flexible part like if you were prototyping a seal or a running shoe

bob

 

[rsanter]

Shrink. The replacement part would be 3-4% smaller than broken original.

you can do that to a degeree.
somepeople will scan the part and then in a modeling program they can upsize the part a percentage to accomdate for the shrink and then they can send the plastic part out to be used as a core to make the mold to cast the final prototypr part

bob

 

[Bolster]

Shrink. The replacement part would be 3-4% smaller than broken original.

Oh yeah! That's right. Would be a real problem for a precision replacement part would it not. For some reason I'd forgotten about shrink.

 

[Kevin54]

Wouldn't they have had a copy (they'd have to machine it to clean up obviously) if they'd skipped the whole high-tech plastic intermediary process, and just cast from the broken original? It's cool, but why was the intermediary step of a plastic copy necessary?

With the plastic part they could do investment castings if they wanted. Basically you send the plastic part to a foundry. They coat the plastic with a porcelin slurry. Then the plastic is melted out and the porcelin is filled with a molten aluminum or material of choice. Then the porceling is put into a vibrating tumbler where the porcelin breaks off leaving the casting material.
Another reason for the plastic part is like Jay Leno stated....you can try it for fit and funtionality before going to the trouble of machine a solid piece from metal.

 

[The Rusty Gear]

you can do that to a degeree.
somepeople will scan the part and then in a modeling program they can upsize the part a percentage to accomdate for the shrink and then they can send the plastic part out to be used as a core to make the mold to cast the final prototypr part

bob

That was exactly my point! You need the intermediate "plastic" step to "upsize" the pattern!

 

[The Rusty Gear]

Oh yeah! That's right. Would be a real problem for a precision replacement part would it not. For some reason I'd forgotten about shrink.

As you mentioned, It really depends on the part. I cast a replacement thermostat housing for my 4Runner using the broken part as a pattern. The mounting holes just had to be drilled out a little further on the tabs. I moved the pattern around a little in the sand to "Oversize" it a little before removing the pattern in order to compensate.

 

[The Rusty Gear]

With the plastic part they could do investment castings if they wanted. Basically you send the plastic part to a foundry. They coat the plastic with a porcelin slurry. Then the plastic is melted out and the porcelin is filled with a molten aluminum or material of choice. Then the porceling is put into a vibrating tumbler where the porcelin breaks off leaving the casting material.
Another reason for the plastic part is like Jay Leno stated....you can try it for fit and funtionality before going to the trouble of machine a solid piece from metal.

Nope. Investment casting is done with WAX! Don't know what kind of plastic the printer uses, but if it is a thermoset it will BURN, not melt! Most plastics are too viscous to be properly drained from an investment cavity.

 

[kartracer55]

The 3d scanners are pretty legit. The technology has been around a while and is used on a much larger scale for many many things.

Looks to me like the machine is just some variant of SLA?. While it is neat, we have one at school and its kinda lame. Great for "prototyping", but the downside is it isn't a functional prototype most of the time. Pretty fragile stuff. You can make "functioning" ball bearings though. That is pretty neat.

Now you want something REALLY badass...

http://en.wikipedia.org/wiki/DMLS

Direct Metal Laser Sintering. Fully functional parts right before your eyes.

 

[X1 Mike]

The one thing I like with this technology getting cheaper and the point I’m trying to get across is that high end tech is now available to the masses. One thing I used to do in the tool & die business is to make the foam die shoes for large body side dies. These foam die shoes would be taken to a foundry cast in metal and we would get them back, mount the tool steels etc. If I came up with an idea of a part to manufacture on a small scale I could make a prototype out of any material even foam in any shape and digitize it to produce on CNC. With some of the smaller machines available today you could have a mfg. company up and running for less than the cost of a new car.

 

[r6_cannibal]

The one thing I like with this technology getting cheaper and the point I’m trying to get across is that high end tech is now available to the masses. One thing I used to do in the tool & die business is to make the foam die shoes for large body side dies. These foam die shoes would be taken to a foundry cast in metal and we would get them back, mount the tool steels etc. If I came up with an idea of a part to manufacture on a small scale I could make a prototype out of any material even foam in any shape and digitize it to produce on CNC. With some of the smaller machines available today you could have a mfg. company up and running for less than the cost of a new car.

to CNC my mill, cost was about $300, granted i built my own controller. for forging parts, the refractory is about $100 and the crucible was about 60 dollars. With lost foam casting, I can make just about anything out of aluminum. Cnc the foam compensated for shrinkage, coat the part in a type of plaster, set it in sand, pour the aluminum, final machining on the cnc, and the part is done. Very inexpensive and very easy to make parts from aluminum.

 

[Bolster]

I cast a replacement thermostat housing for my 4Runner using the broken part as a pattern...

You cast your own Toyota engine part, rather than buy a replacement at the dealer? That is way cool. You are my hero of the day. Wish I had that capacity (and skill).

 

[KarateBoy]

to CNC my mill, cost was about $300, granted i built my own controller. for forging parts, the refractory is about $100 and the crucible was about 60 dollars. With lost foam casting, I can make just about anything out of aluminum. Cnc the foam compensated for shrinkage, coat the part in a type of plaster, set it in sand, pour the aluminum, final machining on the cnc, and the part is done. Very inexpensive and very easy to make parts from aluminum.

I think it would be cool to do things like this. How do you calculate the shrinkage?

 

[Elroy]

How do you calculate the shrinkage?

This would be a good start:

http://www.shelmetcastings.com/shrinkage-allowance-for-metal-casting.html

Lost wax is also known as investment casting

 

[Skyline]

Shrink. The replacement part would be 3-4% smaller than broken original.

I guess if you're looking to duplicate an original exactly, if the original is cast...so should be the replacement. But it seems to me if funcionality is the only goal, going right to CNC would certainly not give you any shrink issues, and be a lot more simple. I would assume you could edit the scan at some point to remove a defect...you wouldn't want your new replacement part to have a crack machined in.

 

[Garage_Mahal]

I would assume you could edit the scan at some point to remove a defect...you wouldn't want your new replacement part to have a crack machined in.

Yes, there is an art and a science to editing scanned parts on the tube.You can recreate entire missing segments on the tube. Not for the faint of heart when the point clouds contain tens of millions of points though.

Or you can do it the old fashioned way and use body filler on the part and give it to your machinist. The part Jay used for a demo probably didn't need to scanned to that level of accuracy for use in an old steam engine.

 

[r6_cannibal]

I think it would be cool to do things like this. How do you calculate the shrinkage?

Simple as increasing the size by a percentage in autocad based on the alloy of aluminum used.

you can find general approximate percentages online but the best thing to do is find a metal supplier you like and stick with them and get a system down. The accuracy of the casting is mainly for quicker milling time, because any chips go right back into the furnace