Monthly Archives: September 2013

So… What Have I Printed?

Since I got this printer on 9-3-2013, it’s been used for over 238 hours of printing (that’s over 9 hours a day of printing!).  So, what have I printed?

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Successful prints:  These either worked as expected the first time (about half of them) or required several iterations to get them ‘done’.

  • Pen & pencil holder (downloaded from Thingiverse)
  • Rifle scope zoom rings (that I designed)
  • 3 versions of RCBS decap / primer catchers (Thingiverse / revisions by Lon)
  • Derim cup (that I designed)
  • Piston, rings and rod (downloaded from Thingiverse)
  • Core swaging catch tray (that I designed)
  • Bleed tray (that I designed)
  • Core shaker (that I designed based on another’s work)
  • Customized iPhone cases (downloaded from Thingiverse & modified)
  • Ford V6 engine block (downloaded from Thingiverse)
  • Clips to mount plexiglass to the printer frame (that I designed)
  • Model railroad track clips (downloaded from Thingiverse)
  • Proof of concept for brass sorting (that I designed)
  • Reloading die holder (that I designed)
  • Lego-style pieces (downloaded from Thingiverse)
  • A plastic bullet (that I designed)

Works in progress:  These still require some work…  either I need to modify the design (the die plate holder), or the model is complex and requires a more advanced approach to printing.

  • Model windmill (downloaded from Thingiverse)
  • Reloading die plate holder (that I designed)

Several of these were just for fun – to see what the printer would do.  Most, though, solved specific problems.  Would I have spent money on equivalent commercial products?  Probably not for many of them.  In many situations, the equivalent products cost more than I was willing to pay (I know…  so I bought a 3D printer instead).  However, some are invaluable – and others are interested in purchasing them.  In any event, I’m still blown away by the technology & the possibilities – I’m turning bits into useful objects right here on my desk!

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Printing Cool Stuff

Sometimes you have to print stuff – just because you can!

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This is a Ford V6 engine block, uploaded to Thingiverse by engineers at Ford.  It was ‘simplified’ by another Thingiverse user to ease the burden on computers that have to crunch all of the slices.  I’m amazed at the detail!  It took about 7 1/2 hours to print.  All I need now are pistons, crankshaft, cam…

 

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Printing, posting and proofing

Just a few days ago, I took the leap.  So far, so good!  I’ve had what I consider good interest, and I’m working on filling orders.  Not every ‘order’, though, is for reloading / swaging accessories.  Friends learn about the printer and their minds go into high gear…  I just printed 52 .027 gauge train track connectors!

The good?  Things are running relatively smoothly.  The printer is running great – glad it doesn’t need sleep because it’s not getting any.  I’ve built process around my activities.  The processes include having a Google Docs spreadsheet where I’m tracking orders & milestones; part of that spreadsheet is posted publicly and linked to the site so customers know where their order stands.  I’m also scheduling print jobs to maximize output (Google Calendar) – some jobs run longer than others, and I need to be here to take them off the build plate before the next job can start.  I’ve stayed current on e-mail, private messages and posts on the relevant forums. I’ve had a chance to catch my breath, go back and make sure my i’s are dotted and T’s crossed – fixing a couple of typos here and there on the blog.  I think I’m in a good spot at the moment.

The bad?  Not enough time in the day to learn more.  Lon has pointed me to many things that I still need to learn & explore – settings for the slicing software, tweaks to settings and other things to try.  Things are settling down after the initial push, so I hope to have time soon to dive into those things. I don’t want selling a few things to overshadow the fun of learning & exploring this new technology.

Gotta run – Google Calendar is reminding me that it’s about time to swap out another piece! And, off to work!

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Speed to Market – Transformational Technology

After about 3 weeks with my printer, I’ve decided to take the leap and offer 3D printed objects for sale.  To be sure, it’s a bit of a leap of faith – I’ve gone from “hobby & home use” to taking orders in that period of time, with no previous 3D printing experience.

One of the interesting aspects of this is demonstrating how this technology can truly revolutionize ‘speed to market’.  When I got the printer, I had a couple of ideas for products that would serve a niche market… In the week between ordering the printer and receiving it, I quickly evaluated and then learned (just the basics) of a CAD program.  I spent several days of that first week designing several of my ideas, turning them from thoughts to bits.  Then, over the next 19 days (which included a 4 day business trip), I was able to learn the basics of printing, iterate through several design changes on each of the items I’d drawn, send them for testing and offer them for sale. In less than 3 weeks.  That’s transformational technology! In that same time period, I’ve come to know (virtually) a couple of people – Lon in particular – who have provided timely advice that’s minimized my learning curve and kept things that could have derailed on track.  That highlights another key aspect of the technology curve – how the internet is central to enabling this journey.  I’m pointing out the obvious now, but with a reason – I remember a few short years ago when this would have been impossible. Even IF I had a 3D printer then, my ‘market’ would have been folks I could reach through classified ads in specialty magazines delivered by the postman.

WIll it be successful?  Can the printer (and can I) deliver on the expectations I’ve set?  Time will tell.  To be sure, there are some risks.  But, I’m also taking a measured approach – this isn’t an endeavor where I’ve taken out ad space on a major site and shouted from the mountaintops…  I’ve identified a narrowly focused niche market (that I’m part of) and provided small solutions to every day problems.

There are a couple points of potential failure that need to be considered.  Will the (relatively) unproven printer be up to the task?  What if demand exceeds my capacity?  Will I ever sleep?We’ll know soon. I’m writing this in the hours before openly announcing product availability on a forum. I’ve hinted at offering them for sale – and my latest post on one forum generated significant interest… and there is a line forming.  Wow.

So, here we go!  With the encouragement and support of several key people, I’m off!

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My First Two Weeks of 3D Printing

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Now that I’ve had my 3D printer for 2 1/2 weeks, I thought I’d share a few things I’ve learned (in no particular order):

  1. I wish I’d paid more attention in geometry!  I jumped into the deep end and started designing my own stuff. That requires some math & geometry (neither are particularly strong suits for me).  Now, don’t let that scare you – it’s not that hard, and today Mr. Google is there to help.
  2. Frankly, it’s been about what I expected.  The printer itself has just worked.  I haven’t had any issues where I wondered whether or not the printer was doing what it’s supposed to do.  On the other hand, there is lots of futzing to do – lots of little lessons to find (lots of reading on 3D / CAD forums); some obscure tips & tricks.  Fortunately, I came across Lon, who I consider a mentor, who has been INCREDIBLY helpful.  He has several years of this under his belt and shares things that help, when I need to know them.  If you’re thinking about getting one of these printers, and all you’re going to do is print objects from Thingiverse, you may not have as many of these trials & tribulations.
  3. It’s fun to gauge people’s perceptions of 3D printing. As expected, most don’t think it’s in the home user’s domain yet.  Others, who are kind of like me, are at the tipping point – about ready to make a decision to get one.  The absolute best way to get someone’s imagination flowing is to hand them an object printed on a 3D printer.  Amazement always follows.
  4. It’s not as expensive as you think!  I was conversing with a friend who lives across the country and who follows me on FaceBook.  She said something like ‘…but it’s so expensive!’ (and she was thinking like $10k kind of expensive!).  No – it’s about 10% of that!  Still, not cheap – but what did a good laser printer cost 10 years ago?  What does a good, fast computer cost today?  They’e in the realm of reality if you do your homework.  But, you can also pay lots more than I did for one.  Shop wisely.
  5. I’ve lost lots of sleep.  I want to perfect the things I’m designing, and I want them to be right – right now.  Between drawing the parts up in CAD and printing them, it takes time and commitment.  For better or worse, I’m the type that digs in and won’t let go until I’ve got something solved… and that takes time.  For the past two weeks, I’ve spent about 2 hours in the morning before work and 4 or 5 hours in the evenings on 3D printing related things. And, when printing overnight (which is about nightly), I’ll get up in the wee hours and kick off another copy or another design.  I’m at the age where I need to get up a couple of times a night, so that just works out if timed right :).
  6. The printing itself is slow.  Just now, I printed a small piece that’s a proof of concept for a larger model (one functional part that will be replicated out in a pattern). It took 9 minutes to print.  But, in final form, the whole piece will take 3.5 hours to print.  Some things I’ve made take over 7 hours to print.  You’ll need to schedule your printing / designing time wisely.
  7. For the above reasons, I need to think things through before printing.  “Measure twice; print once“.  I’ll learn that someday.  I’m not the most patient person in the world, and instead of just printing & seeing how it comes out, I need to be a little more thoughtful about whether I’ve double checked all of the small details, because they matter.
  8. It helps to be handy, but you don’t have to be a master craftsman either.  Pretty simple stuff, really – like going to Home Depot for plexiglass & putting holes in it (used to make side covers to control the temperature); mixing up acetone & ABS to make ABS slurry; measuring with calipers.
  9. Organization is hugely important!  This applies to physical stuff (components, pieces & parts) but maybe more importantly on the computer.  I’ve generated hundreds of files between the CAD drawings and the sliced model files; many of them are different revisions of the same pieces.  Having a structure & file naming scheme is important, otherwise I’d be lost trying to remember which one worked the way I intended it.
  10. While it’s not quite ready for every household, I think it’s far enough along for more than people realize.  They just don’t know it yet…  Soon.  Very soon.

Are you ready for a 3D printer yet?

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Core Shaker – Working Copy

I now have a full size, working copy of the core shaker.  I tweaked the design last night based on the ideas of a friend (the sides or ‘fence’ is permanently attached to the top tray instead of the original design, which was a box that both trays sat in.

I tested it, and it works! There are still a few kinks to work out (the biggest one is that the cores are catching on the edges of the jackets).  But at least I know I won’t be manually placing a core into each jacket when my final set of swaging does arrives!

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Putting the Pieces Together

Kind of like building blocks, I’m taking what I learn and then adding to it.  In this case, the original design for this core swager was 100 holes.  Because of the warping problem, I divided the part into quarters and printed them separately.  I still had some warping, but after printing the first few my ‘mentor’ suggested something that helped a ton!  Since I knew the basic concept worked, and while I worked on solving the warping / shrinking problem, I printed enough pieces to make a whole top piece.  Next step – combine them.

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When I brought up glue, my ‘mentor’ seemed to scoff (if you can infer emotion in an e-mail without emoticons).  Not glue, ABS slurry (pieces of ABS melted in acetone).  Easy enough and I certainly have enough scrap ABS built up!  While I don’t know the strength of the joint yet (it’s still drying), this is a common practice for 3D printers.

The other obvious takeaway here is that 3D printing isn’t limited to objects that are the size of the build plate.  Pieces can be printed and bonded as necessary to create a much larger object. Even a car!  Check this out.

The pieces that make up this top plate of the core shaker are a hodgepodge of proofs of concept; the amount of warping on the bottom varies as I worked out the kinks.  The white one?  Yeah, that’s what happens when you’re tired & trying to get a print started before going to bed.  I told it to use the wrong extruder (…that was loaded with white ABS instead of black). Oh well – great visual reminder for me to check all of the details twice (or, from an earlier post, ‘measure twice, print once’.  Yes, sometimes I’m a slow learner.

 

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Working Proof of Concept

After several setbacks, I have a working proof of concept for a core shaker, adapted from a design from a member over on CastBoolits!  It’s not perfect, but it works.  But, there are still several problems to solve:

  1. I’m still fighting some lifting / warping on the bottom, even though this print is much smaller.  However, even though the bottom is a little bowed, it will still work.  It’s not as pretty as it could be though.
  2. My hole sizes may be a little large.  I’m finding that with ABS, holes (in particular) tend to shrink from the size they’re drawn at.  So, after my first prints, I had to enlarge the holes but I didn’t know for sure how large to go.  After a few trials, I went with a 7.4mm (.291″) on the drawing.  That translated to a 6.6mm (.259″) hole in the plastic.  That works for the jackets, but the cores tend to hang up on the edges of the jackets as they’re going in the holes.  This may also be solved by making one of the trays a bit higher (so the core is at a steeper angle falling into the hole and less prone to catch on the lip of the jacket).  Or, a combination of both.
  3. Combining pieces together.  As drawn, I included a small cut / relief on the base edges thinking they’d align well and be a place for the glue to go.  But, with the warping, those edges may need to be at the top, and I’ll glue these together sitting face down.  These pieces will make a good test for that.
  4. Layer alignment.  Right now, nothing is implemented to align the top & bottom layers.  I’m thinking of putting little nubs on the bottom layer that would align with small divots on the top layer.
  5. The fence.  This part (should) be simple :).  This should just amount to a box.  But, given the warping / lifting, I anticipate the size of the completed box is going to cause some problems.

So, in case I jumped into the weeds and the concept of this ‘core shaker’ doesn’t make sense, here’s a brief explanation.  The cores need to go into the jackets; doing it manually takes time. After stacking the black tray on the white tray & surrounding both with a fence (the index cards for now), empty jackets are poured onto the top of the black tray.  Shaking the whole thing around causes the jackets to tip & fall heavy-end first into the chamfered holes.  Then, cores are poured on top of the black plate and shaking again causes the cores to drop down the holes and into the jackets.  Lift off the top plate and you have them all sitting up, ready to be picked up individually for the core seating die.

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