3-d printing and composites help?
3-d printing and composites help?
Hi All,
I'm working on a little project and trying to come up with the most cost effective way to produce it. 3D printing is one option we're looking into but I'm not real familiar with 3d printing. Ok, I'm not at all familiar.
I'm trying to find out a very rough cost to print a small wing shape out of aluminum or some type of high strength plastic/composite that can be easily bonded or machined.
Also looking for recommendations on a composites shop in the US that does good work for a fair price. Any recommendations?
Jarrod
I'm working on a little project and trying to come up with the most cost effective way to produce it. 3D printing is one option we're looking into but I'm not real familiar with 3d printing. Ok, I'm not at all familiar.
I'm trying to find out a very rough cost to print a small wing shape out of aluminum or some type of high strength plastic/composite that can be easily bonded or machined.
Also looking for recommendations on a composites shop in the US that does good work for a fair price. Any recommendations?
Jarrod
3D printing, metal, and cheap do not belong in the same sentence. What size of part are you making? I'm guessing you're looking at additive process cause raw material block size is large from an odd shape maybe?
If you send me a pic of what you're trying to do I can help you with the best process to make it.
If you send me a pic of what you're trying to do I can help you with the best process to make it.
3D printing is good for doing a low-strength mockup part for a fit check, but we're still a long way from being able to cheaply 3D print high-strength parts.
What sort of size are we talking about here?
What sort of size are we talking about here?
Not sure on exact dimensions but something like a 4"x24" wing element that must handle high loads, and has multiple compound curves that would make it difficult to produce using normal wing manufacturing practices.
I would probably be looking at a CNC with a 4th axis supported on both ends to make that. Could also 3D print from ABS in 8" sections, joint them, then smooth with acetone vapor bath and use as a mold to overlay carbon on. Even a light infill would be just fine there.
If it was a constant section then standard hot wire methods would work. Could also create a negative like they do to make composite piping.
Several different ways to get it done but an ABS printed core would how Id try just to try it. Would end up like a complex honeycomb structure.
If it was a constant section then standard hot wire methods would work. Could also create a negative like they do to make composite piping.
Several different ways to get it done but an ABS printed core would how Id try just to try it. Would end up like a complex honeycomb structure.
Oh, and I would do sections only because my machine only does 10"x12" and pushing the outside edges doesn't make for the best prints. You can have things printed that big easily through 3D systems.
The problem I'm seeing is with the mounting. It would need to have threaded inserts of some sort in the ends (where end plates typically mount) and would need to support several hundred pounds of load.
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is this for an Andrew Brilliant designed piece?
i agree with cnc process if it's going to be a stress member.
also, that several hundred pounds of load could be significant more when you consider G force and bumps on track.
i agree with cnc process if it's going to be a stress member.
also, that several hundred pounds of load could be significant more when you consider G force and bumps on track.
Last edited by honda-guy; Aug 2, 2016 at 05:53 AM.
CNC'd foam wrapped in carbon would probably be the best bet here for a one off piece?
If you wanted to make a mold for low rate production, the ABS might work as a core for a mold. I'm not too sure it would hold it's shape with the heat you get while laying up the mold though?They do have an "Ultem" ABS that is a lot stronger and deals with temps better then the standard ABS so maybe it would hold up. It's way more costly then the standard ABS materials.
3D ABS printing is usually done based on material quantity but you can also control the internal structure to make it essentially hollow.
If you wanted to make a mold for low rate production, the ABS might work as a core for a mold. I'm not too sure it would hold it's shape with the heat you get while laying up the mold though?They do have an "Ultem" ABS that is a lot stronger and deals with temps better then the standard ABS so maybe it would hold up. It's way more costly then the standard ABS materials.
3D ABS printing is usually done based on material quantity but you can also control the internal structure to make it essentially hollow.
Its doable and the process would be something similar to this.
Have someone who is well versed with CAD make the 3D part. Then have them convert that 3D part into a 3D printing file format like .stl
Upload the part file to a 3D printing company website that can build it according to your dimensions.
I have used Shapeways and Sculpteo in the past but I think your overall part dimensions might not work. They will give you a selection of materials to choose from. Certain materials are way more expensive to 3D print than others.
Its possible to print the part in alumide and then use that for testing. Also after the part is printed you can make a mold of it and then make it out of a different material.
Have someone who is well versed with CAD make the 3D part. Then have them convert that 3D part into a 3D printing file format like .stl
Upload the part file to a 3D printing company website that can build it according to your dimensions.
I have used Shapeways and Sculpteo in the past but I think your overall part dimensions might not work. They will give you a selection of materials to choose from. Certain materials are way more expensive to 3D print than others.
Its possible to print the part in alumide and then use that for testing. Also after the part is printed you can make a mold of it and then make it out of a different material.