Category Archives: WORKSHOP

I enjoy designing helpful tools & items for my Workshop. It is as much a hobby as it is a project for me. Therefore, if an item is something designed for my own person workshop (or a friends workshop)… I will probably Categorize it as a ‘Workshop’ item along with some other category such as ‘Brainstorming’ or ‘Concept’, etc. This will be a great category to look back at if I have a free day to work on something in the workshop and wish to see what items I have thought up over the past weeks or months… I probably will have a lot of unfinished ‘WORKSHOP CONCEPT’ items :-)

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)

 

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

3D Printed Household Items

An alternate name for this Post could be:  🙂
Why Your Parents ( or Spouse) Should Let You Buy a 3D Printer

The ABS & PLA Filament 3D-Printer I have for Household Projects

Most of the projects presented on this site are 3DP or Workshop related …

bluDRO Electronics Box 3D-Printed for a Friend’s Project

For example, these photos are from a collaboration with Al to make a 3D Printed box for his blu-DRO Controller which allows individuals to use their Android Tablet as a Digital Readout on their Milling Machine or Metal Lathe.

3D-Printed Bluetooth DRO Mounts

bluDRO Control Box for Milling Machine Digital Readout

3D Printed Household Items

For this post, I would like to show 3D-Printed Household items which I made on my own personal 3D printer as inspiration for others as to what YOU can make at home with a 3D-Printer.

Each item will have a link for more info and/or CAD & .STL files 🙂

ARLO Wireless Security Camera Mount

ARLO Security Camera 3D Printed Mount

Made this 3D Printed ceiling mount for a 100% wire-free, weatherproof, HD ARLO Security Camera that allows me to easily remove the camera to change the batteries every few months.

Even when the bottom screw is loosened the camera stays in place on the 3DP mount due to the camera’s back magnet still touching the mount’s back bolt, allowing me to grip it securely while standing on a ladder.

When I put the camera back on the 3DP mount after changing the batteries, it magnetically clicks in place between the sides holding the camera secure.  This allows me to release my hold on it so I can tighten the lower mounting screw.

Transparent CAD View Showing How the ARLO Camera is Mounted

Not everything created for the household is a complicated 3DP design as shown with these simple 3D Printed Cord Wraps that use Elastic Hair Ties …

3D-Printed Cord Wraps

3D Printed Cord Wraps Made with Hair Ties

It is very common to end up with only a few wraps of filament on a spool, not enough to make the next print, but too much to waste…  So I decided to make a few designs for items I could print when I was at the end of a roll.

Even did a Filament Weight Test to know exactly how much I could print.

Only Had 17 Wraps of Filament Left on the Spool

I use these ‘Hair Tie’ Cord Wraps on so many items that I am constantly having to print more … sometimes even when I am not at the end of a spool.

Close-Up of the 3D Printed Tab Used as Part of the Hair Tie Wraps

Spend so much time designing SolidWorks CAD items on the computer that, many years ago, I built a Computer Stand with a swing over monitor and switched my office to a LazyBoy chair ~ It is an incredibly comfortable work space!

LazyBoy Chair SolidWorks CAD Work Area

I set items I am measuring on top of the Computer Stand, so wanted to keep it clean and needed a good place to store my headphones within easy reach.

Used the Side Supporting All-Thread as a Place to Hang My HeadPhones

The logical solution was to use the all-thread side supports on my computer stand and design a hanger for the headphones to keep them out of the way.
( They don’t affect the Hard-drive *wink* )

3D Printed Hanger for Headphones on Side of Computer

When adding the photo above, I noticed the little 3D printed ring I made for my iPhone’s neck strap that keeps my clumsy hands from dropping my phone.

The strap ring is a good example how small of parts can be 3D-Printed 🙂

Small Ring Used to Secure the Strap on my iPhone

ANTS … ANTS … and More ANTS!!!

Sometimes the 3D Printer can make items very quickly that are needed in unusual shapes which would be hard to make any other way …

Like many homes we had a mini-ant summer invasion … and by mini I mean the size of the ants … the invasion was massive … Ants everywhere so we needed a solution quickly … Called the exterminator but they would not guarantee they could get rid of mini-ants … So had to come up with a solution of our own.

Borax and Honey Ant Bait Box Created with 3D Printer

The solution was using a Borax & Honey Ant bait mixture that the ants would take back to their nest and kill future ants from coming into the house.

Also needed a way to lure the ants to the bait without pets getting to the honey … Something low-profile that could be placed in areas pets can not reach.

Ant Borax & Honey Bait Pyramid created with SolidWorks CAD

It only took about 15 minutes to draw up this ANT BAIT PYRAMID in SolidWorks CAD Software and 3D Print several for around the house.
.STL 3DP files can be found on GrabCAD:
https://grabcad.com/library/ant-bait-pyramid-3d-printed-1

Within 24 hours we did not see another ant for the rest of the year, and each early summer we get the same Ant invasion; however, every year it is gone within 24 hours using these Ant Bait Boxes.

Video of Ants on the Borax & Honey Bait Box:
https://youtu.be/TkAyW4mN60o

YouTube Video Showing the Ants Attracted to the Honey in 3DP Bait Pyramid

Turtlebutt the Amazing Adopted Desert Tortoise

We have a Desert Tortoise who is part of the Nevada Tortoise Adoption Program whereby Desert Tortoises that are injured, or born in captivity, must be hosted by volunteers in their backyards.

Turtlebutt is a good sort, he never bites people, very friendly, eats better organic food than we do … and most of all he likes to motor around the backyard somewhat like a bulldozer on legs.

Turtlebutt Giving the Eyeball Look with Food Stuck to his Face

He has grown considerably over the years causing an issue with the Patio bench he likes to walk under … He is a straight-line walking kind of guy, so we had to come up with a solution to raise the bench out of his way so he didn’t keep dragging it across the patio … even though seemed to enjoy moving it each day.

Link to Story:  3D-Printed Bench Leg Extensions

3D Printed Bench Leg Extensions for ‘Turtlebutt’ the Tortoise

SIMPLE HOUSEHOLD PROJECTS …

I mention a lot that it is the simple things that make a 3D printer helpful …

We had a Window Cleaning Squeegee and the perfect place to hang it in the kitchen pantry but didn’t have the perfect hanger.

Once again … The Solution was to 3D Print a Hanger 🙂

3D Printed Squeegee Hanger

3D Printed Hanger for Window Squeegee in Kitchen Pantry

All the items kept falling over in the racks below the Kitchen sink …

Under Kitchen Sink Rubber Band Hooks

3D Printed Elastic Band Hooks for Under Kitchen Sink

Occasionally it is nice to be able to hang items like swimsuits outside to dry, so 3D Printed Laundry Clip-On Hooks that fit on the back of the outdoor patio furniture, as-well-as on a Fold-Out Laundry Rack.

3DP Laundry Hooks for Hanging Extra Items on Drying Rack

Ya Gotta have Swizzle Sticks for New Years Eve!!!

.STL Files for Swizzle Stick can be found on GrabCAD:
https://grabcad.com/library/2016-2017-swizzle-sticks-3d-printed-1

Happy New Year 3D Printed Swizzle Stick

We have an elderly cat that came to live with us many years ago when she was 10 years old … and now at 18 she likes to sleep on my lap when I work on SolidWorks CAD drawings in my LazyBoy Computer Chair.

There was no place to put my keyboard without disturbing her sleep, so quickly 3D-Printed a keyboard mount that connected to my monitor and now Rosie-Cat gets to sleep whenever she wishes.

Keyboard Monitor Mount So Cat May Sleep on My Lap While Working

Last summer some friends invited me to a 4th of July event ~ I sent mini SG Gibson guitar models as a thank you since they are fans of Gibson Guitars.

I wanted a custom mini-stand, so designed & 3D Printed this version …

Mini Gibson SG Guitar Stand

3D-Printed Mini-Guitar Stand for a Model SG Gibson Guitar

Lots of Uses for a Household 3D-Printer!!

3D-Printing 4 More Rubber Band Hooks for Under the Kitchen Sink Drawer

I was intimidated the first time I used my 3D-Printer; however, now it is just another tool to make things … and the best part is once you press the start button you can walk away and work on other items (or go to bed) and come back later and the 3D Printed item is finished.  Yay!! 🙂

3D-Printers may seem like they take a long time to print items, but if you are doing something else during that time the 3D-Printer is making your part, then really it is like getting 2 items done at the same time.

I Enjoy Helping Others with their Just-for-Fun 3D Printing Designs

If you get a new 3D-Printer and find yourself stuck on how to draw a household solution … Drop me a comment on here, or @MetalDesigner on Twitter, and we can see what we can come up with for a solution just for the fun of it.

CHEERS!!    Charles Marlin ( @MetalDesigner )

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3D Printed Band-Saw Fixture

My 3D-Printer is making me Lazy ( and I Love it )

Steel Channel Workshop Press

One can assume there are many ways to make angled steel washers, and probably even more places to buy several.

However, it was 10pm at night and I needed 32 Angled Washers in the morning and a way of making them.

As usual I looked to the 3D-Printer for a quick & easy solution.

Washers Angled on One Side and Flat on the Other

Luckily, years earlier, I didn’t listen to warnings from naysayers that said ABS filament 3D-Printers were just toys and could not make usable parts… because my workshop is full of ‘usable’ 3D printed parts.

Sometimes the simple items are the most helpful …

Post about: 3D-Printed MT-3 ABS Inserts

.STL files for 3D Printing items can be found on GrabCAD.com

3D-Printed MT-3 Shelf Inserts CAD Files

3D Printed Shelf Inserts for MT-3 Tooling

 

3D-Printed Knob to Open/Close Hydraulic Bottle Jack Valve

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

 

3D Printed Hole Measurement Inserts

3D-Printed Threaded Measuring Inserts

 

3D Printed Drill Bit Holder

3D-Printed Drill Bit Holder for the Side of the Drill Press

 

Tabletop Drill Bit Stand

3D-Printed Tabletop Drill Bit Holder

 

Pipe Curve Scribe Guide

3D-Printed Pipe Curve Scribe Guide

 

3D-Printed Angle Washer Band-Saw Fixture

3D-Printed Band Saw Fixture for Cutting Angled Washers

 

Long story short – I designed a fixture to fit inside the clamp on my metal band-saw to cut angled washers.

3D Printing the two parts for the Band-saw Fixture

In the morning, my plan was to bolt together a project made from steel Channel with inner sides that have an approximate 9 degree angle.

Angle Washers on Channel Bolts

When cutting several holes in the sides of the channel I ended up with a few ready-made angled washer plugs and bored them out with the metal lathe to fit 3/8″ bolts … However, I needed a lot more angled washers.

Angled Slugs Create when Cutting 1″ holes with a Hole Saw

Looking at the Hole-Saw slugs gave me the idea of creating more angled washers.

Boring 3/8″ Holes in the 3/4″ Rod on Metal Lathe

I used 3/4″ mild steel rod and bored 3/8″ holes in each end of the rod …

3D Printed Angle Cutting Fixture and 3/4″ Metal Rod on Band Saw

The plan was to cut angled (9 degree) cuts on each end and then cut another set of straight cuts on each end to create washers …

Metal Rod in 3D Printed Band Saw Fixture

Was not sure if the 3D Printed ABS would hold the rod tight enough in the band saw’s clamp, so I put some vise-grip pliers on the other end of the rod to keep it from spinning …

Overhead View of the Band Saw Cutting the Angled Washer

The 3D Printed ABS split fixture more than held the rod tight enough …

Angled Washer after it was cut off Rod

Every cut creates an Angled Washer from the 3/4″ round stock …

Overhead View of the Band Saw Ready to make the Straight Cut

Outer edge starts out straight … then the first cut creates the 9 degree side of the angled washer … then rod flipped around …

Band Saw Cutting the Straight Cut Side of Washer

After both ends are cut angled, then the 3D Printed fixture is removed for the straight cuts.  Many Washers can be made switching back and forth from Straight to Angled Cuts

Switching back and forth from Straight to Angled Cuts

Process continued until I had enough angled washers to complete my project.

Another View of the Fixture holding the Rod after the Angled Cuts

It worked great!!

Once again ~ Sometimes the simple items are the most helpful.

Finished Angled Washers for Bolting items to the Channel

While I felt a bit lazy starting a 3D-Print and then going to bed to wake up the next morning with a finished part – I am quickly getting over the guilt. 😉

BTW ~ The reason the Workshop Press looks so unusual is because the parts store together as a Press, however, it can transform into 3 additional workshop tools … Sheet Metal bending Press Brake, a Pipe Bender, and a Hoist.

CHEERS!! . . . CHARLES MARLIN ( @MetalDesigner )

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3D Printed Hydraulic Jack Knob

20 Ton Hydraulic Jack with 3D Printed Knobs

This is another ‘simple’ 3DP ( 3D-Printed ) item to make life easier …

Hydraulic Jack 3D Printed (Open/Close) Knobs Project

I am designing a 36 inch long Sheet Metal bending Press Brake for DIY ‘Maker’ workshops and decided to use a Low-Profile Hydraulic Bottle Jack.

Compact Workbench 36 inch Wide Metal Bending Press Brake

Press Brakes are designed based on what material the user wishes to form …

Sheet Metal Thickness Dimensions Used to Figure Out Bending Tonnage

This new workshop sheet metal bending press brake will have an adjustable Vee-Die that will open from 1/2″ to 1.5″ across the V.

Vee-Die Examples Showing the Sheet Metal Bend Radius

A common method of calculating the ‘Air Bend’ Vee-Die distance is using the metal’s thickness multiplied 8 times, or 6 times for a tighter bend radius.

Link for more about Bending Sheet Metal with a Press Brake

If one knows the Vee-Die opening distance and the metal’s thickness then the bending tonnage can be calculated for different widths of metal.
( CINCINNATI  has a great Press Brake Load Calculator Webpage )

CINCINNATI Press Brake Load Calculator Website

First step was to decide on the maximum thickness of metal I will be bending, so I measured the 10 gauge mild steel I had in the shop. ( 0.136″ thick )

While I may bend thicker metal at lengths less than 36″, decided 10 gauge mild steel would be the max thickness bent at 36″ length in a 1.5″ V-Die.

CINCINNATI Press Brake Load Calculator said I would need 17 Tons to bend 36″ of 0.136″ thick mild steel in a 1.5″ V-Die.
http://www.e-ci.com/press-brake-tonnage-load-calculator/

Tonnage Calculations for bending a 36″ length of 14 Gauge (0.075″) Mild Steel

While I may bend 0.136″ thick metal from time to time, 16 gauge and 14 gauge will probably be the metal thicknesses I use the most for full 36″ bends.

BTW ~ CINCINNATI make Amazing metal bending Press Brakes and if I had room in my little shop I would buy one; however, since space is the limiting factor, I am going to make a small worktable size press brake.
( View CINCINNATI’s Press Brake Models )

Torin 20-Ton Stubby Bottle Jack purchased at LOWES

I found a low-profile Hydraulic Jack that fits the metal bending specs given by the Tonnage Calculator, so purchased the TORIN 20-Ton Stubby Bottle Jack online and picked it up later that day at my local LOWES store.

SolidWorks CAD model of the 20-Ton TORIN Low-Profile Bottle Jack

First thing I did was draw the Jack into SolidWorks with adjustable features …

SolidWorks Allows the Bottle Jacks Parts to be Adjustable

Knowing the Jack’s exact lifting dimensions will be helpful in future designs …

Since this Hydraulic Bottle Jack will be used with a metal bending press brake I may need to release the pressure quickly with one hand while supporting the metal with the other hand.

Hydraulic Jack Handle with the Replacement 3DP Open/Close Knobs

Using the handle’ notched end to Open & Close the hydraulic valve may be cumbersome at times; therefore, I needed to come up with a valve solution.

Concept for the Large Hydraulic Bottle Jack Knob

Decided to use SolidWorks to draw up Large & Small versions of knobs to Open and Close the jack’s hydraulic fluid value.

SolidWorks 3D Printed Concepts for a Large & Small Open/Close Knobs

3D-Printed the Knobs with a tight hand press-on fit and they worked great!!

3D-Printed the ‘Quick-Turn’ Knob for the Low-Profile Hydraulic Bottle Jack

I had black filament on the AFINIA 3D Printer so used it, but I will probably use an easier to see ‘brighter color’ in future versions of the Open/Close valve knobs.

Close-Up View of the Finished Large Knob for the Hydraulic Bottle Jack

Once again ~ Sometimes the simplest items are the most helpful 🙂

… CHEERS!!!

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3DP Hard-Hat Cooling Mount

Concept of the 3DP Mount Created with SolidWorks CAD Software

This is why I like SolidWorks CAD Software & 3D-Printing!!!  ( 3DP )

Wanted an unusual shaped mount, so decided to quickly draw & 3D-Print it.

Part 1-of-2 for the Mount that fits inside my Hard-Hat

When visiting job-sites in Las Vegas many require everyone to where a hard hat.

Last year I put some ice packets inside my hard hat to see if I could create a cooling effect to make it more comfortable when visiting job-sites during those hot 110 degree sunny Nevada days.

Ice Packets Being Tested inside a Hard-Hat Purchased from Home Depot

Usually I am just there to get measurements of something I need to design for the project; unfortunately, sometimes it means standing in the hot sun for hours.

The Cooling Test worked, so this year decided to make a permanent mount …

Screen-Capture Showing the AFINIA 3D-Printers Software

Designed a 2-part mount using SolidWorks and 3D-Printed the 2 parts …

Printing Part 2 of 2 of the Hard-Hat 3PD Mount

Nice thing about 3DP is one can draw very complex shapes without having to worry about draft angles which would have to be considered if injection molded.

Just-for-fun I added a mounting area for a temperature sensor inside …

Finished Part 2-of-2 for the Hardhat Mount

Bolted the mount to the hard-hat and everything still is located 3/4″ above my head allowing the cool air to slowly drift down over my head during hot days.

Later I will test different sealed cooling ice packets with a temperature sensor.

Finished 3D-Printed Mount inside Hardhat

Just another fun 3D-Printing (3DP) Project 🙂

… CHEERS!!!  

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Powder Coating Oven 3DP Parts

SolidWorks Rendering of the Powder Coating Oven Electronics Box

Earlier this year I started buying parts to make a Powder Coating Oven.

Controls inside the finished PCO Control Box prior to wiring

Controls inside the finished PCO Control Box prior to wiring

I will try to post images later to help others make their own PCO controller …

Controls Shown in PCO Control Box Prior to Wiring

The goal is to have a Portable Powder Coating Oven (PCO) with removable panels that can be configured into different shapes to allow for powder coating rectangular boxy shaped items as-well-as long thin items by heating the same volume of air with 2 heating elements. ( Total of 5170 watts )

Powder Coating Oven on Wheels allowing to to be moved anywhere in shop

Also a portable (Plug-in) PID Controller for the Powder Coating Oven … with the bonus that the PID Controller can also be used with my Beer Home Brewing Equipment and a future outdoor Meat Smoking Hut 🙂

Portable Powder Coating Oven PID Temperature Control Unit

For this Project my plan was to first draw in all the purchased parts and then start designing the rest of the items using SolidWorks CAD Software.

CLICK HERE to Learn more about Powder Coating

Powder Coating Oven Parts drawn into SolidWorks

Powder Coating Oven Parts drawn into SolidWorks

Attempted to order as many parts as possible off of AMAZON.com

Dayton 1TDV2 High Temperature Blower, 115 Volt, 129 CFM

Dayton 1TDV2 High Temperature Blower, 115 Volt, 129 CFM

As they arrived, I weighed the parts and drew them into SolidWorks …

Measuring a part's weight with a digital scale

Measuring a part’s weight with a digital scale

SolidWorks allows me to make the CAD part’s weight, and center of gravity, the same as the real-world part, so completed Assemblies are the correct weight.

The weight of the actual real-world part matches the SolidWorks CAD part

The weight of the actual real-world part matches the SolidWorks CAD part

SolidWorks also allows users to make Photo-Realistic renderings of the parts for presenting a visual of how real-life item will appear when finished.

SolidWorks Renderings of Parts for the Powder Coating Oven

SolidWorks Renderings of Parts for the Powder Coating Oven

I decided to 3D-Print many of the parts for the Oven’s Control Box …

3D-Printed Side Air Hole Vent Covers for Electronics Box

3D-Printed Side Air Hole Vent Covers for Electronics Box

First designed the Powder Coating Oven’s Electronics box with SolidWorks …

( Click on any image to see a larger view of the photo )

SolidWorks CAD Rendering showing the side Vent Covers

SolidWorks CAD Rendering showing the side Vent Covers

One of the benefits of using a 3D-Printer is designing any shape needed without worry of ‘draft angles’ which are required to make plastic injection parts.

For example, I wanted to be able to switch out different size/models of square shaped PID Controllers & Digital Timers.

Rounds Cutouts in Sheet Metal to Mount Square Controls

Rounds Cutouts in Sheet Metal to Mount Square Controls

So I designed and 3D-Printed a mounting setup which allows ‘square’ controls to go in a ’round’ hole easily drilled with a 2.5″ hole saw using a drill press.

Mounts to put a Square PID Control into a Round Hole

Mounts to put a Square PID Control into a Round Hole

Also designed and drew up some Cord Stop Clamps  ( .STL Files )

3DP Cord Stop Clamps to Keep Cords from Pulling Out of the Control Box

3DP Cord Stop Clamps to Keep Cords from Pulling Out of the Control Box

I like to show lots to dimensions in my drawings to prevent mistakes 🙂

Drawing of the Powder Coating Oven’s Front Control Panel

Tested the 3D-Printed parts, and the purchased parts, within the sheet metal cutouts prior to welding & painting the Electronics Box.

Testing 3D-Printed Parts in the Sheet Metal prior to painting

Testing 3D-Printed Parts in the Sheet Metal prior to painting

The electrical Terminal blocks I bought didn’t work, so I designed some …

Uploaded the 3Dp .STL files to GrabCAD ~ Link:  3Dp Terminal Blocks

SolidWorks Transparent View of the Electrical Connection Terminal Block

SolidWorks Transparent View of the Electrical Connection Terminal Block

Didn’t have 1/8″ thick Copper so found some Aluminum angle in scrap bin …

Drill and Tap Size Dimensions for creating the Terminal metal bar

Drill and Tap Size Dimensions for creating the Terminal metal bar

Drilled and Tapped the Aluminum and then cut it to the correct size …

Tapping Threads in the No.6-32 and No.10-24 Connection Holes

Tapping Threads in the No.6-32 and No.10-24 Connection Holes

3D-Printed one for White wires, and another for Black wires, and the ABS 3D-Printing material acts as an insulator for the 120V electrical connections.

Aluminum or Copper Flatbar sections press into a slot in the ABS Terminal Block

Aluminum or Copper Flatbar sections press into a slot in the ABS Terminal Block

The Cover keeps the screws from falling out even if they become loose …

Different Size Wire Terminal Ring Connections can be used on Terminal Bar

Different Size Wire Terminal Ring Connections can be used on Terminal Bar

I will probably switch out the Aluminum with Copper flatbar when I get some.

3D-Printed ABS material Cover protects the metal area of the connections

3D-Printed ABS material Cover protects the metal area of the connections

A specific feature I wanted for this (PCO) Powder Coating Oven was the ablity to know the cost of the electricity used while Powder Coating parts.

Amp Volt Watt Multi-Meter purchased from AMAZON.com

bayite Amp Volt Watt Multi-Meter purchased from AMAZON.com

The multi-meter comes with a ring which needs to go around the L2 electrical wire to know the Amps being used, so I designed and 3D-Printed a stand.

3D-Printed Amp Meter Ring Stand fits inside Electronics Box

3D-Printed Amp Meter Ring Stand fits inside Electronics Box

Below is a SolidWorks rendering showing the wiring and Amp Ring Stand.

SolidWorks Rendering showing how the L2 White wire fits into Ring Stand

SolidWorks Rendering showing how the L2 White wire fits into Ring Stand

The baylite Multi-Meter shows the Voltage, Current, Power, and Energy.

SolidWorks Rendering of the kWh Meter for Powder Coating Oven electrical cost

SolidWorks Rendering of the kWh Meter for Powder Coating Oven electrical cost

3D-Printed ABS material provides protection from other wiring in the box …

The finished 3D-Printed Amp Meter Ring Stand Mount for Powder Coating Oven

The finished 3D-Printed Amp Meter Ring Stand Mount for Powder Coating Oven

Tested each of the parts prior to mounting the in the electronics box ~ In the photo below I have the baylite meter setup to test 120v amperage; however, the meter is wired to 240V power in the Powder Coating Oven control box.

Testing the kWh Amp Meter unit prior to installing the the Electronics Box

Testing the kWh Amp Meter unit prior to installing the the Electronics Box

In future posts, after fully testing out the Powder Coating Oven, I will show the wiring in SolidWorks, which is easier to view than the real-life wiring because I will be able to hide, or make transparent, other items in the box to show specific wires going to specific items.

SolidWorks Transparent View of Powder Coating Oven Control's Wiring

SolidWorks Transparent View of Powder Coating Oven Control’s Wiring

I have already uploaded many of the CAD parts to GrabCAD.com

https://grabcad.com/charles.metaldesigner/projects

SolidWorks Rendering of Switches used in the Powder Coating Oven designs

SolidWorks Rendering of Switches used in the Powder Coating Oven designs

Tried to keep most of the items as Single part files; yet, still allow the parts to be adjustable, such as allowing switches to be viewed as ON or OFF.

The SolidWorks CAD switch can be set to show it as ON or OFF

The SolidWorks CAD switch can be set to show it as ON or OFF

Made the gap adjustable so the switch fits on other material thicknesses …

Gap of the Switch can be changes to match the thickness of metal

Gap of the Switch can be changes to match the thickness of metal

The LED Readout numbers can also be set for Tutorials & User Manuals …

The AUBER PID Controller keeps the the Oven's temperature consistent

The AUBER PID Controller keeps the the Oven’s temperature consistent

I try to use metal from my scrap metal bin to make equipment for my shop and sometimes the metal is heavier than I would normally use.

For example, the sheet metal for this PCO (Powder Coating Oven) Control box is 0.135″ thick and I would probably normally use 0.075″ thick sheet metal.

Welding the Powder Coating Oven Control Box Sides Together

Welding the Powder Coating Oven Control Box Sides Together

After drilling & cutting all the holes, I welded the Control box sides together …

The finished sheet metal PCO (Powder Coating Oven) Control Box

The finished sheet metal PCO (Powder Coating Oven) Control Box

Since this unit is for my shop I painted the PCO Control box Flat Black …

The PCO Control Box with Bolt-On Top & Back Plates

The PCO Control Box with Bolt-On Top & Back Plates

The Top & Back plates bolt-on to make the inner Controls easier to wire …

Painted the Powder Coating Oven (PCO) Control Box Flat Black

Painted the Powder Coating Oven (PCO) Control Box Flat Black

After the paint cured I started adding the controls & switches …

Installed the the Front LED Lights, Switches, Timer, and PID Controller

Installed the the Front LED Lights, Switches, Timer, and PID Controller

Noticed I was one ON/OFF switch short … They came in a Pack of 5 … *sigh*

Back on AMAZON to order more … For some reason I thought there was 6 🤔

All the Powder Coating Oven electronic parts fit in the box as designed

All the Powder Coating Oven electronic parts fit in the box as designed

After tests realized I didn’t need the Air Cooling fan but added one anyway.

Next Step is to add the 240V Outlets to each side of the PCO Control Box

Next Step is to add the 240V Outlets to each side of the PCO Control Box

Everything on the PCO is powered from outlets & extension cords, because this is a portable Powder Coating Unit that can be taken to different locations.

This Electronics box can also control a Meat Smoker & a Home Brewing system.
(  I wanted a multi-use Control Box for future projects ~ Whoo Hoo!!  )  😜

Front Blue LED lights-Up when the Blower Fan 120V outlet is switched ON.
Front Green LED Lights-Up when Oven Light 120V outlet is switched ON.

Fan Side View of the Powder Coating Oven's Control Box

Fan Side View of the Powder Coating Oven’s Control Box

The Amber Light on the front lets users know 240V power is plugged into the Control box … When dealing with 240 Volts – Safety, Safety, Safety!! ⚡

In addition,  the Amber LEDs on each side of the control box light-up when the Contactor Switch is providing 240V power to the 240V side outlets that are connected to the Powder Coating Oven’s Heating Elements.

Vent Side View of the Powder Coating Oven's Control Box

Vent Side View of the Powder Coating Oven’s Control Box

The White LED Lights-Up when 120V Power is plugged into the Control box.

I’m having ‘Laser Etched’ Metal Labels made up to explain Control functions.

View showing the 120V Outlets for the PCO's Blower Fan & Oven Light

View showing the 120V Outlets for the PCO’s Blower Fan & Oven Light

Additional Views of the Controls for the Powder Coating Oven …

Top-View Powder Coating Oven Control Box

Top-View Powder Coating Oven Control Box

Fan Side-View Powder Coating Oven Control Box

Fan Side-View Powder Coating Oven Control Box

 

Vent Side-View Powder Coating Oven Control Box

Vent Side-View Powder Coating Oven Control Box

 

There is a Switch to Turn ON/OFF the Air Cooling Side Fan

There is a Switch to Turn ON/OFF the Air Cooling Side Fan

 

3D-Printed Side Air Vents fit into 2.5" Holes cut with a Hole Saw

3D-Printed Side Air Vents fit into 2.5″ Holes cut with a Hole Saw

That’s All for Now 😜

Emergency Stop added to the front of the PCO Control Box

Emergency Stop added to the front of the PCO Control Box

I found the eStop button and added it to the PCO Control Box design …

SolidWorks Photo-Realistic CAD Rendering showing the Emergency Stop

SolidWorks Photo-Realistic CAD Rendering showing the Emergency Stop

Made a temporary stand/mount for the PCO Electronics Control Box …

I think PCO Stand/Mount sort of looks like a Robotic Kangaroo Rat

I think PCO Stand/Mount sort of looks like a Robotic Kangaroo Rat

Already has the nickname of ‘Roo-Rat’  😜

Click on image to see a larger view of PCO Controller on Stand/Mount

Click on image to see a larger view of PCO Controller on Stand/Mount

I uploaded my SolidWorks ‘Working CAD Files’ to GrabCAD for anyone that would like to see how I tested the wiring.

The wiring in the model is not complete, but it will show how I wired the Auber PID Temperature Control, as-well-as the Inkbird Timer Control and the Digital Amp/Volt Meter.

GrabCAD Link: https://grabcad.com/library/powder-coating-oven-wiring-1

Prototype Wiring CAD Model Files Uploaded to GrabCAD.com

The Powder Coating Over Controls I used were:

Auber SYL-2342  PID Temperature Control
( SYL-2342 version is for Contactors not SSRs )

INKBIRD IDT-E2RH  Timer

Eaton C25BNF240A  Compact Definite Purpose Contactor

Bayite AC 80-260V LCD  Watt Multimeter Ammeter Voltmeter

AC Infinity AXIAL 8038   Muffin Cooling Fan, 115V AC

Erb44t10010  2,585 watt Heating Elements ( 2 )

If you have any wiring/control Questions send me a comment  🙂

… CHEERS!!!

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

3D-Printed Bench Leg Extensions

Turtlebutt Getting Up-Close and Personal with the Camera

Turtlebutt Getting Up-Close & Personal with the Digital Camera

Turtlebutt ( The Amazing Adopted Desert Tortoise ) is part of a Nevada adoption program whereby protected Desert Tortoises that are injured or born in captivity cannot be released back into the wild.

Turtlebutt Feeding Out in the Grassy Area in the Back Yard

Turtlebutt Feeding Out in the Grassy Area in the Back Yard

By law Desert Tortoises may not be removed from the State of Nevada; therefore, homeowners will volunteer to let a Desert Tortoise live in their enclosed backyard area and make sure they are fed and have a place to hibernate underground during the cooler Nevada months.

If a family is moving out of the State of Nevada, they or the adoption program, must find a new home in Nevada for the protected Desert Tortoise to live & hibernate … and that is how we came to live with Turtlebutt the Tortoise.

Completed Patio Bench with Leg Extensions and Threaded Levelers

Completed Patio Bench with Leg Extensions and Threaded Levelers

Turtlebutt is very friendly and will come over to visit if you are outside, but he is a bit of a bulldozer when moving from one point to another, and if something is in his way he will go over it, or under it, or drag it with him.

Rub Marks from Turtlebutt's Shell When He Goes Under Bench

Rub Marks from Turtlebutt’s Shell When He Goes Under Bench

As Turtlebutt has grown over the years, he has started dragging the Patio Bench with him more and more, to the point it seems like he enjoys it … But we like to keep the bench in one place, so decided to raise the bench a little so he doesn’t drag it with him as he crosses the patio.

3D-Printed Leg Extension with Threaded Bench Leveling Foot

3D-Printed Leg Extension with Threaded Bench Leveling Foot

Later this year when it is not 110F. in the workshop, I will cut and TIG weld the Aluminum side supports at a higher position and possibly arc the supports a bit to account for Turtlebutt’s growth.

As a quick fix this summer decided to 3D-Print some Bench Leg Extensions …

SolidWorks CAD Software Transparent View Showing Press-in Nuts & Bolts

SolidWorks CAD Software Transparent View Showing Press-in Nuts & Bolts

I drilled holes & tapped threads for one 8mm machine screw and four small #6 screws into the bottom of each bench leg … Then used the SolidWorks design shown above to press-in 1/2″ nuts to mount the Threaded Foot Pad Leveler bolts into the 3D-Printed Leg Extensions.

It Would Take 9 Hours to 3D-Print all 4 Parts at Once

It Would Take 9 Hours to 3D-Print all 4 Parts at Once

While I could have 3D-Printed all 4 Leg Extensions at once, the printing process would have taken 9 hours and I wanted to be able to test one of the Leg Extenders prior to printing the rest.

It would not have been an issue to do a 9 hours print, because after you press the START Button, you can go to bed or walk away and do something else and come back 9 hours later and the parts will be done … Feels like getting to work on two projects at once when items are 3D-Printing.

Leg Extensions Printed on the AFINIA H-480 3D Printer

Leg Extensions Printed on the AFINIA H-480 3D Printer

In the Photo above, I set the finished 3D-Printed Leg Extenders on the Printing Platform to show the size of the items in relation to the 3D-Printer.

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

Larger Front Leg Extender Shown in the AFINIA 3D-Printing Software

Larger Front Leg Extender Shown in the AFINIA 3D-Printing Software

Since I wanted to test the size and fit-up of just one of the Leg Extenders first, I opened up the Large Front Leg Extender .STL file and 3D-Printed it using AFINIA‘s  ‘ Natural ‘ Color PLA 3D-Printing Filament

( Would have printed them black but did not have enough black filament )

SolidWorks CAD Software View Showing the 4.5 Degree Base Angle

SolidWorks CAD Software View Showing the 4.5 Degree Base Angle

Due to the shape of the original bench design, the Back Leg Extenders needed to have a 4.5 degree base angle to match the angled Aluminum legs.

Smaller Angled Back Leg Extender Shown in AFINIA's 3D-Printing Software

Smaller Angled Back Leg Extender Shown in AFINIA’s 3D-Printing Software

No worries, the 3D-Printer can print a RAFT of support material to build up on the platform to print items that don’t touch the printing platform base.

RAFT Material is Removed from Parts after being 3D-Printed

RAFT Material is Removed from Parts after being 3D-Printed

Once the parts are finished 3D-Printing the extra support material can easily be pulled off revealing the 3D-Printed parts …

Yellow Lines Show the Location of the Extra PLA Filament RAFT Support Material

Yellow Lines Show the Location of the Extra PLA Filament RAFT Support Material

Had just enough of the AFINIA Premium PLA Black Filament on the Spool to print the Foot Pads that press onto the Hex Ends of the Zinc coated Steel Bolts.

Three Foot Pads being Printed at Once after 1st one was Test Printed

Three Foot Pads being Printed at Once after 1st one was Test Printed

As before, I printed just one Foot Pad to make sure it would press on tight, and then printed the final 3 Foot Pads together on the 3D-Printing platform.

Close-Up View of the 3D-Printed Leg Extension on the Bench Leg

Close-Up View of the 3D-Printed Leg Extension on the Bench Leg

Once the Patio Bench Leg Extension parts finished 3D-printing, I then screwed them onto the bottom of the legs using the tapped threaded holes …

Close-Up View of the Threaded Leveler Bolt Screwed into Extension

Close-Up View of the Threaded Leveler Bolt Screwed into Extension

Next ( prior to painting ) pressed the black Foot Pads onto the bolt heads to act as threaded Leg Levelers … They worked as expected stabilizing the bench.

Bench Turned Upside-down Showing the Leg Extension & Leveler

Bench Turned Upside-down Showing the Leg Extension & Leveler

Painted the Zinc coated bolts black so they would blend into the black bench …

Threaded Foot Pad Leveler prior to being painted black

Threaded Foot Pad Leveler prior to being painted black

After testing all the parts, I decided to test the threaded levelers on the Patio.

Leg Extensions Mounted on Bench ready to be Painted Black

Leg Extensions Mounted on Bench ready to be Painted Black

Before painting the Leg Extenders, the White filament color made the bench look like it was doing a Michael Jackson or Elvis ( white socks ) impression.

Testing to Make Sure Bench Threaded Levelers Work Correctly on Patio

Testing to Make Sure Bench Threaded Levelers Work Correctly on Patio

The bench was rock solid stable on the Threaded Leveling Foot Pads so I painted all items black and once dry put the bench back on the patio.

Finished Patio Bench Raised to Allow Turtlebutt Easily Walk Under

Finished Patio Bench Raised to Allow Turtlebutt Easily Walk Under

The next time Turtlebutt is under the Patio Bench I will get a Photo of him.

Those are Actually Berries *grin* ... Turtlebutt Does NOT Ever Bite People

Those are Actually Berries *grin* … Turtlebutt Does NOT Ever Bite People

… CHEERS!!

UPDATE:

Turtlebutt went under the bench today with lots of clearance!!

Turtlebutt Walking Under the Raised Patio Bench

Turtlebutt Walking Under the Raised Patio Bench

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