Category Archives: CONCEPTS

Concept — A list of ideas and/or descriptions of an idea that has developed into a design CONCEPT through the use of CAD mechanical design Software and descriptive notes. Might just be words or might include ‘Photo-Realistic’ renderings & images . CONCEPTS can develop into real-world PROJECTS.

Markforged Part Design-01

Old and New Versions of 3D Printed Pipe Drilling Guide

I am using SolidWorks CAD Software to draw New Parts, as well as re-drawing many of my Old Parts, so that these new designs can be 3D-Printed with an amazing new type of 3D-printer which creates stronger 3D-Printed items …

On the Side are Recent Posts I have made detailing 3D-Printed Projects >>

3D-Printed Ring to Create a Pipe Hole Drilling Guide

The advantage of creating your own 3D-Printed Tools & Parts is you are NOT subjected to the limitations of Off-the-Shelf parts

Want a special tool for your Workshop? – 3D Print it!  

Need a Custom Fixture for Assembling items? – 3D Print it!

Sometimes the simplest items are the most helpful …

3D-Printed Open/Close Knob for Hydraulic Bottle Jack

TOOL & EQUIPMENT DESIGN

We design items based off of the equipment available to produce those items.

In the past humans used wood, then brass, bronze, iron, steel, aluminum …

Different material’s abilities provided new design options; yet, each new material required new fabrication methods & equipment to create parts.

Wood & Metal Vintage Machinery on a Friend’s Family Farm

Metals are strong; however, machining is expensive due to the many different fabrication processes & experience needed to create parts for equipment.

Vintage Metalworking Lathe

Carbon-Fiber parts are lightweight & strong, but required custom made molds & chemicals of which the fumes limit fabrication locations.

Carbon-Fiber Vacuum Forming

In addition, plastic injection molded parts can be made inexpensive only by making hundreds, or thousands, of the same exact part; yet, if a change has to be made it costs thousands of dollars (and may take weeks) to re-machine a new injection mold out of metal.

Plastic Injection Mold Machined out of Metal

The brilliance of 3D-Printing (Additives Manufacturing) is that just about anything one can draw into CAD software can be 3D-Printed into that shape.

Borax and Honey Ant Bait Box Created with 3D Printer

Injection Molded parts require draft angles to get parts out of the mold; however, 3D-Printed parts can be whatever shape you need to create the best part possible for your project.

In other words – You Design your parts for their use, not by what methods you have available to fabricate the parts … Draw the specific part shape you need and then press the 3D-Printer’s  START button.

3D-Printed Parts Can be Carbon-Fiber Reinforced ( Strong & Lightweight )

Need to Change/Update a 3D-Printed Part’s Design?
No worries, just change the design anytime you wish and send the new file to the 3D-Printer.  Within seconds you are making a new updated part.
( No financial punishment for creative design updates )

3D-Printed Design to Hold a Cooling Sensor & Frozen Gel Packs

3D-Printed Hard-Hat Cooling Mount

Finished 3D Printed Part Created for a Las Vegas Collaboration Project

MARKFORGED 3D-PRINTERS

Markforged Stronger 3DP Materials provide more design options…

Markforged launched the first and only 3D desktop and industrial line of printers that smartly embed continuous fiber to created a printed composite part and they introduced a breakthrough method of printing same-day real metal.

Markforged 3D printed parts are much stronger, stiffer and more impact resistant than parts from any other 3D printer.

https://markforged.com/why-markforged/

Composite 3D-Printer Created by Markforged

ONYX and NYLON parts starts with a base plastic filament extruded from the Markforged 3D-Printers first print head.
Parts made of plastics alone have excellent engineered properties such as toughness, stiffness, stability and strength over other plastic printers.

FIBER MATERIALS – Reinforce with continuous fiber for amazing properties through our second print head.
You have a choice of four fiber materials for tremendous boosts in strength, toughness and other properties for the most advanced uses any 3D printer can provide.

https://markforged.com/materials/

Markforged has Many Types of 3D-Printing Materials

3D-PRINTING DESIGNS

I have already posted many examples using metal fasteners (Bolts, Nuts, Screws) in combination with 3D-Printed parts, and have reached the limits of my current 3D-Printer …

3D Printed ARLO Camera Mount

Also, created 3D-Printed shapes to be used patterns for metal casting …

3D Printed Metal Casting Patterns

Unfortunately, I have reached the size & strength limits of my current 3D-Printer and wish to be able to design for stronger 3D printed materials …

ARLO 3D Printed Camera Mount Parts Printed on the AFINIA 3D Printer

MARKFORGED DESIGNS

The goal of my – Designed for Markforged – posts are to create items specifically designed to take advantage of stronger Markforged 3DP materials and the larger 3D-printing platform dimensions.

( Click on images to see a Larger View )

Pipe Hole Drilling Guide SolidWorks CAD Rendering

The equipment and parts one buys online, or in a store, have been designed for general use so as many people as possible can use those items.

Many individuals and businesses cannot use off-the-shelf parts and have to design and fabricate custom made items…

Hydraulic Drilling Reaction Arm

Remote Access Drilling & Foundation Stabilization Equipment

Several years ago I starting working with Bill create ‘remote access’ drilling equipment for Helical Piers & Micro-Piles for foundation stabilization …

Pipes Slide Through Cutoff Guides to Mark Cut Line Location

Every location has different needs so we end up designing & fabricating custom items for different situations …  Some items are for physical work and others are used as guides and/or measuring & alignment.

Not all Locations have this much room around the Pipe

Sometimes holes have to be accurately drilled into pipes in remote locations and/or pipes have to be cut off shorter and the hole re-drilled to match the hydraulic drilling unit’s mounting holes.

Large Diameter Step Drill Bits for Thick Metal

Inside my workshop, it is very easy to cut off the pipe and then re-drill the mounting holes in the correct location, but on the job-site it becomes much harder for workers to do it quickly & accurate with a hand-held drill.

Guide for Drilling 1/4″ Pilot Holes for a final 7/8′ Hole-Saw Cut

There are different types of drilling equipment and each one has a different purpose and method of use … Many times we have to create special tools due to the tight working conditions in remote access areas.

As an example, sometimes there isn’t enough room to use a long spike to line up holes, so I made a short hand-held spike on the suggestion of a worker.

Hole Alignment Spike

View Showing How the Shorter Hole Guide-Spike is held close

It is amazing how much time a simple tool can save on a job, and how much time can be wasted when a process is done inaccurately with the wrong tool.

I use 3D-Printing almost daily to create fixtures for projects in my shop …

3D Printed Band-Saw Fixture

View of 3DP Saw Fixture holding the Rod after 9 Degree Angled Cuts

3D-Printed designs are much easier to create because what you draw can be printed by just pressing the START button and come back later to have a finished part … I’ll go to bed after starting a 3D-Print ~ wake up, and it is done.

SolidWorks Concept Designs for the Old & New Versions

Previously machined a drilling guide out of metal, and it worked great, but keeping track of it seems to be the biggest issue… Also with many job-sites we need a drilling guide in each vehicle so one it is available when needed.

I would show a photo of the original metal drilling guide, but that is part of the problem, we need more than one, because I have no idea where to find it?

Now I can easily 3D-Print several more Drilling/Measuring Guides and don’t have to spend the time machining them, and while they are 3D-Printing I can work on other projects … It is like getting two things done at once.

SolidWorks CAD Software – Transparent View

I decided to make several 3D Printed versions using a combination of Nuts, Bolts, Aluminum flatbar, and 3D-Printed parts …

Design works great, but wanted to make it even simpler so that anyone can push the START button on the 3D-Printer … and then press in a few 1/4″ nuts that can be found at any hardware store in any location where a job is taking place.

Teaching people to start a 3D-Printer is about like starting a Paper printer.

Top View of the Old & New Version

Re-designed the new Drilling & Measuring Guide to be 3D-Printed as one piece and the nuts would press into the 3D-Printed part.

Testing fit up of the 3D-Printed Part with Pipe Curve

For this post, I used SolidWorks CAD Software to cut out a small piece of the design and 3D-Print it as a test items for some of the features …

Would anyone else be able to use this 3D-Printed Drilling & Measuring guide?

Probably Not… but that is the great thing about 3D-Printed items, I don’t have to worry what OTHER people want; instead, I only have to design parts and tools that I need for my projects/business.

Decided to cut out a Section to Test Fit Dimensions

The features added to this 3D-Printed guide are:
– Drilled-out 1/4″ Nuts to align the 1/4″ drill bit for pilot holes in pipe
– Threaded 1/4″ Nuts to allow 1/4″ bolts to tighten guide in place on pipe
– Grooved areas that will hold paint to help locate drilling guide holes
– 3D-Printed 7/8″ Guide holes to check to make sure drilled hole are correct
– Cut guide so Top of pipe will fit into drill and holes will match up
.  .  .

I’m Still Amazed How Accurate 3D-Printed Parts can be Created

If anyone has concerns about the accuracy of 3D-Printed parts you can view the image above – Very Accurate!!

No.6-32 Threads Tapped into 3D-Printed Material

Threads can be tapped in 3D-Printed items, just that same as parts made from other materials … and 3DP holes sizes can be the same as Tap Drill sizes.

Tapping Threads and Pressing Hex Nuts into 3DP Test Part

By testing Hex Hole sizes, you can create a press in fit whereby the nuts do not fall out and can be hidden inside the 3D-Printed part; yet, still allowing the bolt or screw to be tightened from the outside.

Try machining Hex holes inside a round object on a Milling Machine – Not!!

But it’s simple to add Hex holes or shapes to 3D-Printed items … EASY!!

Combining Metal Nuts, Bolts, and Screws with 3D-Printed Parts

Another feature I like to add to my 3D-Printed tools is Paint Grooves …

Testing Blue Paint in the 3D-Printed Grooves

By drawing grooves ( or lettering ) in my 3DP parts, when the paint wears off of the outer surfaces, the paint stays in the grooves showing off lettering or guide lines on the parts …

Sanding the extra Blue paint off with a Sandpaper Sponge

Usually I would paint the entire side and let it wear off on its own, but for this test, I put the paint on with a toothpick then (after drying) sanded the paint off the outer surface.

Used the blue paint I had in the shop, but would probably use a Bright Yellow or Florescent Green on the actual Drilling & Measuring Guide.

Before and After – Blue Grooves

My AFINIA 3D-Printer does not have the ability to print the Drilling/Measuring Guide’s body as one part, so I used two smaller 3D-Printed parts.

With the Markforged 3D-Printer it can be created as one 3DP part.

SolidWorks CAD Software Rendering

I’m sure we will change the design many times as workers suggest new features they would like added to the Drilling & Measuring Guide …

But no worries, unlike having to create a new metal-casting mold, or machine a new part … I’ll just add new features to the SolidWorks CAD design and then just press the PRINT button on the Markforged Printer.

Markforged 3D-Printers

Markforged also has Metal 3D-Printing Technology!! 

https://markforged.com

Markforged Metal 3D-Printer

That’s all for now … More (3DP) 3D-Printed Designs to Come later …

Click Image to View SolidWorks CAD Files and 3D-Printing .STL Files

If you are interested in designing something you feel could be printed out of strong material on a Markforged 3D-Printer, please send me a note.

We can discuss your idea and draw a SolidWorks CAD design … and see how your idea will look as a Photo-Realistic CAD rendering of the 3DP item.

CAD Rendering of 3D-Printed Submarine Toy with GoPro Inside it

Why am I offering to draw CAD items for people to try on Markforged?

Because they are on the correct track by producing 3D-Printers that print materials which can be used in real-world manufacturing & repair shop settings.

Request a Demo on the Markforged Website

WELL DONE MARKFORGED!!

… CHEERS!!   Charles Marlin ( @MetalDesigner )

.    .    .     .

Advertisements

Leave a comment

Filed under 3D-Printing, BRAINSTORMING, CONCEPTS, Markforged 3D-Printer, PROJECTS, SolidWorks CAD Rendering, THOUGHTS, WORKSHOP

3D Printed ARLO Camera Mount

SolidWorks Transparent-View ARLO Camera Mount

Added some extra NETGEAR ARLO Security Cameras inside the house …

Link for ARLO Cameras: https://www.arlo.com/en-us/

ARLO 3D Printed Camera Wall Mount

Needed a camera in an unusual location, so decide to 3D-Print a Mount …

ARLO Camera Mount created with SolidWorks CAD Software

Made the ARLO mount with an Adjustable Angle Ball inside 3DP Clamps …

ARLO 3D Printed Camera Mount Parts Printed on the AFINIA 3D Printer

Started the 3D-Printer, had supper, and when done eating the parts were done.

Tools & Parts to Mount the Netgear ARLO Security Camera

Metal parts: Two No. 8 Screws & Nuts, 1/4″ bolt/nut & two 2″ Deck Screws …

SolidWorks Rendering of ARLO Security Camera 3D-Printed Parts

The older Logitech Security Cameras we use have been phased out, so decided to start using these NETGEAR ARLO security cameras to watch the house and keep track of 17 year old Rosie-Cat when not at home.

Click on Image to View NETGEAR ARLO Security Camera Website

The Camera is easy to adjust and screws lock it tight with the correct view.

ARLO Security Camera 3D-Printed Wall Mount

While installing the ARLO camera Rosie-Cat informed me there were little ants coming in the house which usually happens in the spring and in late summer.

Put out the 3D-Printed (Borax & Honey) Ant Bait Box each time …  They will take the Borax back to the nest and they will be gone in 24 hours … and we not see them again for several months.  Yay!! 🙂

Link for:  3D-Printed Borax & Honey Ant Bait Box

Getting rid of the August 2017 ants with Borax & Honey Ant Bait Box

UPDATE: 24 Hours Later All Ants GONE!! … Works every time!!!

OK … Back to the ARLO Mounts… 🙂

Put the .STL 3D-Printing files for the ARLO Mount on GrabCAD.com

https://grabcad.com/library/arlo-mount-3d-printed-1

.STL Files for 3D-Printing Can be found on GrabCAD.com

… CHEERS!!  

Charles Marlin  @MetalDesigner

.    .    .    .

2 Comments

Filed under 3D-Printing, CONCEPTS, PROJECTS, SolidWorks CAD Rendering

Pam Marlen – Artist (1938-1997)

Art Studio Poster Explaining Pam Marlen’s Glass Bead Making Process

Today would be my mother’s 79th birthday, she passed away in 1997.

Pam Marlen ( Mary Pamela Smith) 1938-1997 Artist

I have very little of my Mother’s artwork, and if not for the kindness of my little brother sending me several items I would not have any.

As-well-as designing Passive Solar Houses, Gardens, and Landscaping – She also created amazing fused glass creations, pottery, glass beads, quilting, water colors, stained glass, and probably many other items I’m not remembering as I write this post.

She would even make the  unusual fun vests she would wear to events …

Back label on Pam Marlen’s ‘Buttons to Beads’ Self-Portrait

Much of my mother’s artwork was sold and anything left after her death was distributed amongst the family; therefore, the stunning Fused Glass pieces are owned by others, but I am very happy to have what might be one of my mother’s only artistic self-portraits.

Buttons to Beads Quilt with Glass Beads by Pam Marlen

Pam Marlen didn’t do anything normal, and if she was going to do a self-portrait of course it would be something unusual like combining Quilting & Glass Bead making to make the portrait of her making Glass Beads …

Paper that was pinned to Quilt – Houston National Quilt and Beads Showing

She also included herself playing with buttons as a child in the portrait …

Pam Marlen as Child Playing with Buttons

All of the Glass Beads attached to the quilt were made by Pam Marlen and they were sewn to the quilt using buttons on the back …

Back of Buttons to Beads Self-Portrait Quilt by Pam Marlen

My mother liked to save items that she didn’t feel were worth selling because there was an imperfection on those items… she didn’t save much but some items had imperfections she liked and would save them inside her studio, just for her own collection.

I’m not sure how many people knew about her ‘imperfection collection‘, but she and I talked about them once and it was fascinating how she liked something special about each one.

Fused Glass Examples in Background

A few years ago I found 2 new glass fusing/ceramic kilns for sale at a very good price and I purchased them … While my mother had taught me a little about fusing glass, I took a private ‘one-day’ class to refresh my memory.

Link to Post: Firebox-8 Kiln Height Extension

This Firebox-8 Kiln’s Temperature is Manually Controlled

Creating Fused Glass artwork is about predicting how it will look when finished semi-melting/fusing together … Thus, having no idea how to predict, I just overlapped interesting colors of broken glass into a pattern.

Cut & Broken Glass in Kiln before 1st Melting

After the first melting the instructor was very let down that the glass had cracked, but being my mother’s son I said, “Oh that makes it even more interesting, lets leave it and do the final melting to fuse it as is” …

Broken Slumped Glass that Broke and Re-Fused in Kiln

The final kiln firing softened the broken edges and created an interesting Fused Glass piece …  I placed it on my dresser and consider it the first of many of my own  ‘imperfection collection’ artwork pieces.

I imagine there will be many future Metal Castings to add to this collection 🙂

First Try and Glass Artwork on My Dresser

In addition to saving imperfect pieces, my mother also would create small pottery pieces that she could use to test out Pottery Glaze formulas …

Mini Glaze-Test Pottery Parts by Pam Marlen

It appears the items my little brother sent to me were part of a Green Glaze test and even these little items had her signature on the bottom.

While I only have test pottery pieces by my mother, I am proud to have those items because that is how I remember her – Always experimenting!!

Bottom of the Green Glaze
Formula Test Pottery by Pam Marlen

She signed all of her Pottery with a PM symbol  (Click images for larger view)

Pottery Signature on Test Glaze items by Pam Marlen

She had shelves of these small glaze-test pottery items in her studio …

A larger piece of pottery that was probably a Green Glaze-Test item

Mary Pamela Smith (Pam Marlen) was born in Tulsa, Oklahoma to E.R. and Mildred Smith on July 31, 1938.
She created most of her artwork in or near Great Falls, Montana.

This looks like a Bowl she used to test some Green Pottery Glaze

The pottery I remember the most as a child was a natural wash look as shown in the image below with hand-touched clay items added to pottery she had thrown on her potter’s wheel.

Natural Glaze with Clay Hard Artwork on Pottery

For years she would make pottery Christmas Ornaments and give them out to friends and family… Many times having us as kids help her.

Received photos of an items my mother made that I had not viewed before …

Hat made for Pat Erickson by Pam Marlen

Pat Erickson sent these photos to me of a hat my mother made for her …

If you enlarge the photo and look closely the bugs on the hat are glass beads.

Hat with Glass Bead Bugs made by Pam Marlen for Pat Erickson

Pat mentioned Pam Marlen made this hat for her birthday 🙂

Hat created by Pam Marlen with Painted leaves & Glass Bead Bugs

Thank You Pat for taking the time to send these photos!! 🙂

.   .   .

Pam Marlen had a stroke at age 58 in April of 1997 while giving a speech to get donations for the flood victims of the Grand Forks, North Dakota flood of 1997… passing away later in the year.

She lived an interesting life … and myself being a Star Trek fan it was almost surreal to come home to visit and learn her quilting group was asked to be extras in a movie directed by Leonard Nimoy… being very private director he would rarely talk to people on set; however, he would come over talk to my mother about quilting and other artistic items.

My mother met SPOCK …Too Cool!!

… MISS YOU MOM  

1 Comment

Filed under CONCEPTS, PROJECTS, THOUGHTS

3D Printed Chocolate Candy Molds

SolidWorks CAD Example of a SafeKids Chocolate Mold Shape

Just for fun several years ago, I showed Carma ( The Coordinator for SafeKids in Grand Forks, North Dakota ) how I could use their 2-Dimensional Logo and turn it into a 3D CAD model that could be 3D-Printed.

The SafeKids 2-D Logo I Turned into a 3-Dimensional Logo for 3D-Printing

Today, I am waiting on some parts to be delivered and decided to use the time to work on some 3D-Printed Chocolate Mold shapes for some friends of mine.

Randi and Carma’s wonderful daughter is getting married to about the coolest guy you’ll ever meet, and they asked if I could take some of their wedding designs and make them into 3-Dimensional CAD models that could be 3D-printed into shapes to make flexible food-grade silicon rubber chocolate molds.

Windsor and Matt the Groom to Be

The wedding chocolate designs are super secret until the wedding, but I thought this would be a good time to show the Chocolate Designs we made for the SafeKids Grand Forks 25th Anniversary Charity Event.

3D-Printed Candy Mold Designs I Made Years Ago

In a previous post, many years ago, I mentioned using 3D-Printing to make Candy molds:  ( Click Link to View Post )
3D-Printing & Plastic Part Molds – July 2013

3D-Printed Candy & Chocolate Silicone Rubber Mold Ideas

There is a helpful website if you wish to learn more about making Silicon Molds:
http://www.makeyourownmolds.com/

One of the Many Websites that Show How to Make Silicon Molds

2-Dimensional SafeKids Logo Designed by Correen for the 25th Year Event

Last year Carma (Mother of the Bride) asked if I would convert a 2-Dimensional SafeKids logo designed by Graphics Designer Correen into a CAD file for making 3D-Printed shapes to use for making chocolate molds for a charity event.

We also made chocolates for some of the event’s sponsors …

Several Different SafeKids SolidWorks Concept Chocolate Design Options

I sent several designs to Carma to review and she decided on the final design.

We Did the Entire Design Project 1600 Miles Between Locations

The process of making 3DP shapes for Candy molds is similar to making mold shapes for metal casting because one has to make sure there are draft angles allowing items to be pulled out of the molds after they cool.

For Candy & Chocolate molds non-toxic safe Food-Grade flexible silicon rubber is used ~ For Metal the 3D-Printed Shapes are pressed into Sand to create hollow areas to pour in molten metal.

Metal Casting with 3D Printed Sand Mold Shapes

To see some metal casting molds I made with SuperDave, click on this Link:
https://ctmprojectsblog.wordpress.com/2016/04/19/aluminum-cast-drill-press-knobs/

We Used SolidWorks Photo-Realistic Renderings to Choose Best Design

I emailed Carma SolidWorks renderings for her to view, and she would suggest design & size changes until we had a final design.

We Finished the Final Designs Several Months Before the Event

After SolidWorks CAD designs were done, I sent them to the 3D-Printing company Shapeways.com to be 3D-Printed.

SafeKids Logo 3D-Printed in High Res by Shapeways.com

I have a 3D-Printer; however, these 3D-printed mold shapes needed to be high-resolution so I sent the .STL 3DP files to Shapeways because they have very expensive 3D-Printers that can print extremely smooth parts.

One of the SafeKids Logo Shapes Used to Make Food Grade Silicon Molds

As usual, Shapeways.com did an outstanding job!!

3D Printed Chocolate Mold Shapes from Shapeways

Once the 3D-Printed shapes were done I tested some Food Grade Silicon and decided that I am not the person to be using sticky items and sent everything to Carma up in North Dakota to make the Silicone Rubber molds.

One of the Many Kits for Making Food Grade Silicone Rubber Molds

Carma, and the folks that helped her up in North Dakota, did a much better job than I could have ever done making the Food-Grade Silicon Chocolate molds.

SolidWorks Rendering to Show How the Chocolates Would Look

I’m not sure of the whole story, but as the event got closer there was an emergency Carma had to work on and her mother (Judy) stepped in saving the day by making hundreds of Chocolates using the silicon rubber molds.

Thank You Judy!!!

Page from the SafeKids 2017 Newsletter

WELL DONE  SAFEKIDS Volunteers!! 🙂

It was fun being a small part of the Event to help SafeKids!!

… CHEERS!!   Charles (@MetalDesigner)

.    .    .    .

 

 

 

 

 

Leave a comment

Filed under 3D-Printing, BRAINSTORMING, CONCEPTS, PROJECTS, SolidWorks CAD Rendering

3DP Drywall Hole Repair

SolidWorks CAD Software Concept of a Drywall Patch

Many ways to do the same thing … and 3D-Printing added another way to patch a drywall hole left over after removing a Flat-Screen TV.

Removed an Old Flat-Screen TV from a Wall Exposing a Hole

In the past, I have patched many holes in walls using a plug cut from old drywall or purchased patching material from a hardware store.

Hole in the Wall after a Flat-Screen TV was Removed

Didn’t have any old leftover drywall material to patch the wall, so decided to draw up a 3D-Printed patch while I was relaxing watching TV in the evening.

So this is basically just for fun to see if I could create a patch with 3DP

Transparent View 3D-Printed Drywall Patch

The hole was 1.42″ in diameter where the Flat-Screen TV’s cords went through the wall to another room, so used SolidWorks CAD software to design a 3DP solution using Stainless Steel finishing nails.

Penny Taped Next to the Hole to Give Size Scale

Once the design was finished I 3D-Printed the two wall hole plug parts …

3D-Printed the Drywall Patch in 2 Parts

Tapped No.6-32 Threads in the outer plug’s holes for attaching inner plug …

Threaded Holes in the Outer Patch Part to Connect Inner 3DP Part

Tested No.6 screws to connect the two 3D-Printed Plug parts and all fit well.

Parts Used to Make the 3D-Printed Drywall Patch

Next tested placing in 1 nail at a time in the center of the plug and pushing them out as they would go into the sheet rock to secure the plug.

Used Stainless Steel Finishing Nails as the Locking Mechanism

The 3DP Wall Hole Plug can be mounted with 3 nails or 6 nails …

The 3DP Patch Locks Using 3 Nails but also can use as many as 6 Nails

Everything worked in the tests so next step was secure it inside the hole …

Supplies for Patching the Wall with Drywall Spackling

Rosie-Cat my SolidWorks Co-Designer fell asleep on the job so was on my own, luckily BKE said she would patch the hole if I would prep the wall.

My Co-Worker Rosie the Cat Sleeping on the Job

Just in case, I attached a string to a long screw in the hole plug so it would not fall inside the wall if I pushed it too far, but the fit was tight and it held very well in place about 0.05″ in from the wall to allow space for spackling the area several times for good coverage.

Attached a string to the 3DP Drywall Plug in case it fell inside the wall

Used all six of the 1″ stainless steel finishing nails about 1/2″ into the drywall.

The Design Allows for One Nail to be Pressed into Drywall at a Time

I could have pressed the nails up to 3/4″ into the drywall but 1/2″ in seemed to secure the plug very well and no need to go deeper and risk drywall cracking.

3D-Printed Patch in the Wall Ready to Have the Inner Plug Part Attached

Screwed on the inner rough finish 3DP part and everything fit well.

Randomly added a lot of Holes & Texture to the 3D-Printed Patch

With my part finished, BKE took over prepping the wall and finished it.

Spackle goes on Pink and turns White when it is Dry

The area will be sanded, textured, repainted, and artwork put on the wall.

3D-Printed Patch and Other Holes Covered with Drywall Spackle

When the artwork is mounted, I will update this post with a photo of it.

The Wall Area after being Patched, Textured, and Painted

The SolidWorks CAD files can be viewed on GrabCAD

3D-Printed Drywall Hole Plug

Click on Image to View CAD Files on GrabCAD.com

Many other ways to do this, but 3D-Printing made it a fun project. 🙂

… CHEERS!!  

.    .    .    .

 

Leave a comment

Filed under 3D-Printing, BRAINSTORMING, CONCEPTS, PROJECTS, SolidWorks CAD Rendering, THOUGHTS

3D Printed Turret Vise/Fixture

Combining Metal Parts with 3D-Printed Parts

SolidWorks Concept Rendering of 3D-Printed Turret Vise

For years I have been combining 3D-Printed parts with Metal Fasteners :
Nuts, bolts, screws, washers, threaded rod, rivets, etc …

3D-Printed ‘Soft-Touch’ Vise for Clamping Delicate Parts

Recently I had the need for a Vise/Fixture with a very soft-touch to clamp delicate parts – and my metal vises were too strong – so decided to 3D-Print a ‘softer’ clamping fixture with Jaws on 2 sides.

GrabCAD Files ~ 3D Printed ‘Soft-Touch’ Vise/Fixture

3D-Printed Dovetail & Threaded Rod/Nut Connection

Actually, could have made it much simpler out of larger 3DP parts and not needed all the connections … but the point was to show Metal-to-3DP part connections, so I worked them into the design.

So please don’t waste your time 3D-Printing this fixture, because I’m only sharing it as a teaching CAD example to show Metal-to-3DP connections.

Vise will be used as a Robotic Fixture connected to Servos

This 2-Jaw Vise is actually a fixture I use for a very specific purpose, and it will not be strong enough for most purposes when used as a table vise.

I am connecting servos to it and wanted to make sure it could not clamp hard enough to crush my fingers without bending first – Hurts but doesn’t crush. 🤣

( Click on any of the images to see a Larger View )

Metal Parts Combined with 3D-Printed Parts

In addition, I like to design projects whereby parts from initial simple projects can later be used in more advanced project assemblies.

Two Vise Options that Use Many of the Same 3D-Printed Parts

Just for fun, I decided to design two Multi-Jaw Fixtures whereby many of the parts from the ‘Soft-Touch’ 2-Jaw can be used to create another rotating 5-Jaw Turret Fixture that could be mounted on my workshop table.

Top-View of a 3DP 5-Jaw Clamping Fixture Design Concept

I’m not going to 3D-Print the 5-Jaw Version because ( as designed ) it would not be strong enough for most uses, but it was fun to show how many little 3DP parts can designed to fit together using Metal-to-3DP part connections.

SolidWorks Design for a 2-Jaw 3D Printed Vise

Reusable 3DP parts are great way for individuals (new to 3D-Printing) to build confidence by printing just a few parts to make an initial project  … then later, they can use many of those early parts to build future projects.

SolidWorks CAD Concept for a 3D Printed 5-Jaw Turret Vise

If you would like to view additional projects I created using 3D-Printed parts combined with metal items – The Links are Shown below :

3D-Printed iPhone Tripod Mount

3D-Printed an iPhone Mount for the 3D-Printed Tripod Mount

Many smaller parts fit on the platform for 3D-Printing at the same time …

3D-Printing Software Predicts the Filament needed & Time to Print

Workshop Video Camera Mount

Upper and Lower 3D-Printed Parts with the Old Aluminum Curtain Rods

I had a lot of fun testing different mounting solutions using 3DP parts …

3D-Printed Camera Angle Adjustment Ball

SolidWorks CAD Files & 3D-Printing .STL files are on GrabCAD

GrabCAD Files ~ iPhone 3D-Printed Mount

GrabCAD Files ~ Workshop Camera Mount

Transparent View Showing How the Ball is Held in Place with Hex Nut/Bolt

Combining Metal with Other Materials

For decades, designers have combined together ‘dissimilar materials’using the materials they had available – to create objects for specific purposes.

Old Farm Machinery Combined Wood with Metal Parts

Years ago, while visiting a friend’s family farm, I noticed how vintage machinery was created using a combination of forged iron parts and wood.

Wood & Metal Vintage Machinery on a Friend’s Family Farm

This gave me the idea of using softer 3D-Printed materials combined with stronger metal fasteners & parts to create very durable items.

Carbon-Fiber 3D-Printed Speaker Box

SolidWorks CAD Concept for a 3D-Printed Carbon-Fiber Speaker Housing

Even if the 3D-Printing technology isn’t available yet for 3D-Printers to make items the size – and out of the materials wished for – I still continue to design items, preparing for future 3DP fabrication methods.

3D Printed Clone Part Designs

Section-View of 3D-Printed Vise connected with Metal Screws & Nuts

Learn By Reverse-Engineering 3D-Printed Assemblies

Instead of writing out in detail how I design each 3DP-to-Metal connection, decided to provide the CAD files for the 3D-Printed Vises on GrabCAD :

GrabCAD Files ~ 3D Printed Turret Vise/Fixture

Section-View of a 3D Printed Part with Threaded Metal Fasteners

You can download the SolidWorks CAD files, and/or .STL files, and review the parts to see the sizes & shapes I used to create 3DP-to-Metal Connections.

Transparent-View showing Straight and Angled Fastener Nut Slots

Specifically made the designs using many different 3DP connection methods.

Split-View of the the Slide Portion of the 2-Jaw Vise

In addition -Uploaded a 3DP Test Block to GrabCAD that you can print out to get the feel of the ‘fit-up’ dimensions used for many of my 3DP Projects :

GrabCAD Files ~ 3D Printed Fastener Test Block

.STL Files for the 3DP Hole Size ‘Test Block’ are on GrabCAD

The Test Block has all the different connections I use in my 3DP projects.

Printing the Metal-Fastener ‘Test Block’ on my AFINIA 3D Printer

Since I live in the United States, I used No.6-32 TPI screws and 1/4″-20 TPI threaded fasteners as the examples in the Test Block; however, the 3DP connection methods will work on all sizes, metric, etc.

Horizontal Vs. Vertical 3D-Printing of Fastener Part Holes

It does make a difference how you place items in your 3D-Printing software to print … Possibly in a future post I will go into greater detail … but if you want to see it for yourself just print the Test Block sitting vertical vs. horizontal on your 3D-Printer’s platform.  ( As shown in above image )

There are 2 Holes in the Test Block the Correct Size for Tapping Threads

You can also tap threads directly into your 3D-Printed parts, so I added 2 holes in the Test Block that are the correct size for tapping No.6-32TPI screws & 1/4″-20TPI threaded fasteners. ( Also the taper for flathead screws )

I Tap Threads directly into Many of my 3D-Printed Metal Casting Patterns

Dovetail joints are a great way to connect 3DP Parts ~ I used a few dovetail connections on the 2-Jaw 3D-Printed vise design.

Also used dovetail joint connections on a project for my friend Keith –

3D-Printed Metal Casting Pattern Created with Notched Connections

Video by Keith Rucker ( Vintage Machinery Museum ) using one of my notched & threaded 3D-Printed Patterns – You can click on the image below if you wish to view the YouTube Video.

Video Link for a 3DP Project I worked on with Keith Rucker

The Same 3DP Parts Used for Multiple Projects

Was talking with Brook (Founder/CEO of Printrbot) who has lots of cool ideas … and we discussed designing some projects whereby each 3DP project builds upon future projects … 3DP .STL part files work on many projects.

It’s about time to upgrade to a Printrbot with a large print platform!! 😜

Click Image to View Info about Printrbot 3D-Printers

For this project used the AFINIA 3D-Printer I have had for many years …

3D-Printing a Vise Part on the AFINIA 3D Printer

I’ve had a Multi-3DP .STL File Project Build concept for awhile, and have wanted to expand it so that when individuals, families, schools, and organizations buy a 3D-Printer they have numerous .STL file project options.

… So they aren’t just printing Yoda Heads* and Fidget Spinners 😜
( *Personal Note ~ Yoda head is VERY cool to print )

Vise Created with 3D-Printed Parts and Metal Threaded Fasteners

The goal is to have thousands of 3DP .STL file options to 3D-Print projects & experiments, whereby many of the 3DP parts already printed will work as parts in other future projects.

While the 3D Printed 2-Jaw Vise/Fixture does have many parts that can be used to make the 5-Jaw Turret Vise/Fixture – I would like future creative & scientific projects to have even more interchangeable parts.

Testing the 3DP 2-Jaw Vise on my Workshop Table

These 3DP Vise/Fixture designs are just examples to show the many different ways to connect 3D-Printed parts with metal items.

3D-Printed Vise Section Side-View Showing Threaded Metal Parts

Made this fixture to hold delicate items that I do not want to crush; thus, this design might not be strong enough as a table vise, and would suggest you create your own 3DP vise design that may work better for your projects.

SolidWorks CAD files and 3D-Printing Files Uploaded to GrabCAD

Hopefully the Metal Fastener Connection information will help. 😀

… CHEERS!!!      Charles Marlin (@MetalDesigner)

 

.    .    .    .

 

1 Comment

Filed under 3D-Printing, BRAINSTORMING, CONCEPTS, PROJECTS, SolidWorks CAD Rendering, THOUGHTS, WORKSHOP

3D Printed Clone Part Designs

Design Futuristic 3DP ‘Clone’ Parts to Replace Items Being Made with Current Fabrication Methods

SolidWorks Rendering of an Adjustable Aluminum Vise

I get asked by engineers & designers how they can improve their abilities …
Yet, what I hear them really saying is – How Can They Stand Out?

( Click on any of the images in the post to see a Larger View )

Encouragement Return Note about Designing Clone 3D-Printed Parts

For years I have been telling Designers the same advice:

“I design ALL my parts 2 ways ~ one for today’s normal fabricating methods CNC lathes, Milling Machines … and then I ALSO design a 2nd 3DP ‘clone part’ that does the same thing, but I design it how it will be 3D-Printed in the future

Remember 3D-Printed parts do NOT need to have draft angles like injection molded parts or Tool entrance paths like CNC machined parts; therefore, you can design parts completely based off how the part will be used, instead of how they will be made …

Hence, parts are much more efficiently designed because there is fewer fabrication limitations and more design is based on part’s use instead of fabrication methods 🙂

Soon there will be much better metal 3D-Printers make Aluminum & Stainless Steel parts, I’ve seen the prototype 3D-Printers and they are amazing!!”

That is a direct quote from one of my Encouragement responses.

Download the Full-Text PDF at this Online Site

I have been following the work of a gentleman by the name of Christoph Laimer for a while, and was excited to see his most recent project a 600 Watt, 3D-Printed, Halbach Array, Brushless DC Motor .

Christoph Laimer’s 3D Printed Brushless DC Motor

Christoph explains his designs better than I could; therefore, I invite you to watch his YouTube videos if you would like more information.

YouTube Link: https://www.youtube.com/user/TheTrueGoofy/videos

Click on Image for Link to Christoph Laimer’s YouTube Channel

Christoph is on the correct path! ~ He is taking common existing items and redesigning them to be manufactured with 3D Printed parts.

His designs are very complex, exciting, detailed, and might seem intimidating to an individual wishing to start the process of redesigning existing parts into 3D Printed parts … but no worries 🙂

If that is the case, I would suggest looking around for easier examples of existing items and start with more simplistic parts to redesign for a future 3D Printing manufacturing process.

Don’t worry about materials or fabrication ~ Design for the item’s USE.

I Have this Vise and it Works Great but Also Made My Own 3DP Vise

Take a field trip to your local store and see what you find …

Pick up items … hold them in your hands … turn them around … test how they function … and then visualize how that specific item could be made differently if there where no fabrication limitations on how it is fabricated.

Future 3D-Printing might be the one case whereby new designers (that don’t understand current fabrication methods) might actually be at an advantage because they haven’t already been subjected to designing based off the limitations of the tools it takes to make items.

Aluminum Vise made with 3Dp Shapes for Metal Casting

Aluminum Vise Created with 3D-Printed Split-Patterns

The CAD & .STL Pattern Files for the Aluminum Vise are on GrabCAD:
https://grabcad.com/library/aluminum-vise-casting-3dp-1

SolidWorks CAD Files & 3D-Printing .STL Files Uploaded to GrabCAD

A while back – I collaborated with David in Oklahoma (SuperDave) to create several different projects using 3D-Printed shapes to be pressed into sand to create hollow molds to pour in molten Aluminum to create castings.

Aluminum Cast Drill Press Knobs

3DP Metal Casting Shapes Used to Create Sand Mold Patterns

I made the 3D-Printed Patterns, and SuperDave Cast the Aluminum …

Aluminum Vise Castings Before Machining

After all the effort to cast the Aluminum … I still had to machine it 🤔

Machining the Aluminum Vise made from 3D Printed Metal Casting Patterns

While it was interesting using a 3D-Printer to create 3DP ‘Sand Mold’ pattern shapes for casting metal ~  The Next Step is to 3D-Print the entire Vise 😜

Just for the fun of it, I decided to redesign a little workshop vise so it can be completely 3D-Printed out of different materials in the future.

Video of a SolidWorks Concept a 3D-Printed Turret Vise

Will show what I came up with for a 3DP Vise in a future Post.  ⚙️

UPDATE: 3D-Printed ‘Soft-Touch’ Vise/Fixture

3D-Printed Vise/Fixture with Dovetail & Threaded Rod Connection

3D Printing will continue to be a Disruptive Innovation.

I enjoy welding and creating parts with my Milling Machine & Metal Lathe as much as any fabricator, but also understand Additives Manufacturing is the future and it will end many machinist’s jobs.  3DP is (and will continue to be) a Disruptive Innovation as outline in an article by Jaclyn Diaz:

Machinists Prepare for Invasion of 3D Printers

Of course, there is going to be issues with Patents and Labor Organizations; yet, other countries like China are not going to slow down, and will continue to move forward with 3DP Manufacturing.

We (Designers) need to let others workout the legal details, while at the same time we continue to prepare for a future dominated by 3DP Manufacturing.

3D-Printing ‘Disruptive Innovation’ Bloomberg Law Article by Jaclyn Diaz

The legal mess will be sorted out while 3D Printing technological advancements continue … and if there isn’t a current 3DP method yet of producing your parts out of a specific material – There most certainly will be in the near future.

Nothing stops you from designing items now — Once the 3D-Printing technology is available, then your (or your company’s) 3D-Printed part designs will be ready to be manufactured.

3DP Titanium Guitar Design Concept

I have a 3D Printed Hollow-Core Titanium Electric Guitar design I’ve been working on which I will present in a future post … but what caught my attention in the photo above was I am still not letting my creativity go wild … because I am designing a 3D-Printed Guitar around existing injection molded plastic guitar pickup and other non-3DP parts!?

So I am scrapping the current 3DP Guitar design, and starting over by designing 3D-Printed guitar pickups as-well-as 3DP switches, connections, and wiring.
WHOO HOO!!  😜

Start Designing Now for Future 3D-Printing Manufacturing

Here are a Few Other ‘Future’ 3D-Printing Concepts to Think About :

Currently items are designed based off what can be machined; therefore, design is driven by tool paths and available fabrication materials.  Yet, with 3D Printed items one doesn’t have to worry about draft angles or tool paths, in fact there may be hidden areas inside 3DP parts that human eyes will never see.

With Additives Manufacturing, one has more flexibility to design based on how the part will be used, not based on what tools it takes to make that part.

HYDRAULICS :

Once 3DP items can withstand at least 5000 psi fluid pressure, 3D-Printing will completely disrupt the Hydraulics industry. Valves & Manifolds will be re-designed to be part of the equipment’s structure.

For example, hydraulic manifolds & valves can be elongated and curved to follow the shape of equipment’s framework — Future transmissions can be built inside a vehicle’s structural parts whereby the fluid cavities are optimized for flow instead of how they can be machined using today’s tooling … Hydraulic equipment designs will become almost organic in shape and hidden as part of the structure, reducing weight and the need for many hydraulic lines and connections that reduce efficiency.

INJECTION MOLDING :

By definition injection molding causes the designer to create parts for the injection molding process first [How to get it out of a mold] and only then can the part be designed as the best possible ‘molded part’ to do the job.

Draft Angles are Not an issue with 3DP ~ Just draw what you need — Draw any unusual shape and then press print and you have a plastic part specifically designed for its use instead of designed based on how it can be produced.

Instead of spending the money upfront to machine molds, future manufacturing will be ‘On-Demand’ or what I like to call ‘Super-Lean’ … Not only do you not make a part until you need it, you have the ablity to change the design of that part within seconds of it being made.

No more need to make hundreds or thousands of an exact part to justify the cost of making the injection mold — Parts can be designed/made on-demand while Additives Manufacturing speed technology will  increase.

MUSICAL INSTRUMENTS :

Many of the musical instruments we use today were designed centuries ago and naturally they used the materials and tools of those times.

Already new musical instruments are being developed using 3D-Printing, but most are still following the old ‘wooden’ and ‘brass’ designs.

Just like the how the first vehicles looked like wagons, it will take time for the old ‘buggy-whip’ design mindset to change into completely original musical instrument concepts.

3D-Printed ‘3Dvarius’ Electric Violin Design

Changing the Way We Think About Design

At first it is hard to design based solely off the’usage‘ of the part. We are so established designing based off what it will take to ‘make the part‘ that sometimes even when not limited anymore we still hesitate.

Just Pretend ~ Pretend there is a way to 3D-Print a Titanium item that can hold 10,000 psi fluid pressure… Then start drawing … don’t worry about tool paths, don’t worry about visual access, don’t worry about current material strengths, or complex shapes, or expense… Just design like you are writing a Science Fiction novel … Because the future is closer than you think.

On day you will wake up and there will be a 3D-Printer making 10,000 psi Titanium parts … and you will have a bank of designs ready to go… I do 🙂

Design Challenges

I would like to see more companies feature GrabCAD Challenges asking the GrabCAD Community to help them re-design their current parts into new designs that will be able to be 3D-Printed in the future.

Click Image for Link to the GrabCAD Challenge Site

I’m going to take my own advice and continue to create ‘Futuristic’ 3D-Printing Concepts for the future … and Please share your future 3D-Printing concepts, I would enjoy to hear them.

CHEERS!! ~ CHARLES MARLIN (@MetalDesigner)

 

.    .    .    .

 

1 Comment

Filed under 3D-Printing, BRAINSTORMING, CONCEPTS, SolidWorks CAD Rendering, THOUGHTS