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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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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3D-Printed iPhone Tripod Mount

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

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

My iPhone seems to take video as good as any other camera, so decided to make a 3D-Printed mount for it to fit on the 3D-Printed Tripod Mount …

SolidWorks CAD Model Concept for the iPhone Mount

SolidWorks CAD Model Concept for the iPhone Mount

Wanted a mount that would connect over the existing cover and would also be easy to quickly slide the iPhone in & out of …

Designed the Concept using SolidWorks CAD Software.

SolidWorks Parts for the iPhone Mount Prepared for 3D-Printing

SolidWorks Parts for the iPhone Mount Prepared for 3D-Printing

After drawing the individual parts, lined them up to prepare for 3D-Printing.

Top-View of the iPhone Mount Parts in AFINIA's 3D-Printing Software

Top-View of the iPhone Mount Parts in AFINIA’s 3D-Printing Software

I use an AFINIA H-480 3D-Printer and it gives a preview of the print platform.

AFINIA's 3D-Printing Software shows a Preview of the Printing Area

AFINIA’s 3D-Printing Software shows a Preview of the Printing Area

Pressed start and 2 hours and 22 minutes later had the iPhone mount parts.

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

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

Moved the 3D-Printer to a better area on the new inside Workshop Table.

3D-Printer moved to it's new location on the inside office Workshop Table

3D-Printer moved to it’s new location on the inside office Workshop Table

The 3D-Printed mount allows photographs & videos to be taken from either side of the iPhone, and the strap can be attached to the Tripod for ‘drop’ safety.

Photo & Videos can be Taken from Either Side of the iPhone on Mount

Photo & Videos can be Taken from Either Side of the iPhone on Mount

The mount is designed for the Ringke MAX  iPhone 6 case.

Ringke Max iPhone 6 Shock Absorbing Case with Neck Strap

Ringke Max iPhone 6 Shock Absorbing Case with Neck Strap

3D-Printing .STL Files can be found on GrabCAD  🙂

… CHEERS!!!

.   .   .   .

 

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Workshop Video Camera Mount

Video Camera Mount for Workshop

Video Camera Mount for Workshop

Digital Camera Mount to leave out in my Workshop to take Videos.

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

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

This project uses old curtain rods that were going to go into the trash …

SolidWorks CAD Concept for the Camera Mount for Workshop Videos

SolidWorks CAD Concept for the Camera Mount for Workshop Videos

Decided to 3D-Print a Camera Mount I could leave out in the Workshop all the time so it would be available if my Tripod was being used on an inside project.

Canon Digital Camera on the 3D-Printed Workshop Tubing Mount

Canon Digital Camera on the 3D-Printed Workshop Tubing Mount

I like the ablity to take digital photos & videos of my projects while they are on the Workshop tables to show the process of fabricating items.

( Example Fabrication Photo from Post:  ‘Shortening My Pallet Jack’ )

Worktable View of Finished welding sides supports & side edges

View of Welding Set-Up for Sides Supports & Edges

Found some old Aluminum Curtain Rods and used them as part of the design to Create a 3D-Printed workshop mount for my Canon Digital Camera.

Thin Aluminum Tubing found in the Metal Scrap Bin

Thin Aluminum Tubing found in the Metal Scrap Bin

Once I knew the Tubing diameters, then designed the parts with SolidWorks.

3D-Printed Camera Angle Adjustment Ball

3D-Printed Camera Angle Adjustment Ball

Added a 3D-Printed Ball to the design to allow for Camera Angle Adjustment.

Camera Adjusts However Needed to Create the Best Video View

Camera Adjusts However Needed to Create the Best Video View

One needs lots of Camera angle options when making Videos of projects …

Hollow Shell Area for 3D Printed Angle Adjustment Ball in the Mount

Hollow Shell Area for 3D Printed Angle Adjustment Ball in the Mount

Once the Camera angle is adjusted using the inner 3D-Printed Ball; then, the outer shell is tightened using a 3D-Printed Knob, Nut & Bolt to lock it in place.

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

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

Whatever is created in CAD can be 3D-Printed on the AFINIA 3D-Printer …

Camera Mount Part Shown in AFINIA's 3D Printing Software

Camera Mount Part Shown in AFINIA’s 3D Printing Software

3D-Printed all the parts using a AFINIA H-480 3D-Printer …

AFINIA 3D-Printer making the Camera Mount Knobs

AFINIA 3D-Printer making the Camera Mount Knobs

I 3D-Printed Hex shaped holes, and for added strength, used 1/4″-20 bolts/nuts & No.6 Machine Screws for this Camera Mount project.

Nuts & Bolts Used to Tighten the 3D-Printed Knobs

Nuts & Bolts Used to Tighten the 3D-Printed Knobs

SolidWorks CAD Software provides the ablity to create Photo-Realistic Renderings, which help designers see what items will look like prior to fabrication.

( Click on the Image Below to see a Larger View of the CAD Rendering )

SolidWorks CAD Rendering of Digital Camera Mount

SolidWorks CAD Rendering of Digital Camera Mount

Photo below shows the finished Workshop Camera/Video Mount …

Canon Digital Camera on the Workshop 3D-Printed Mount

Canon Digital Camera on the Workshop 3D-Printed Mount

As mentioned before, I use an older Canon Camera for Time-Lapse Videos …

Canon PowerShot SD1100IS Camera

Canon PowerShot SD1100IS Camera

Problem with my normal Tripod is it traps the bottom hatch from opening.

Opening the Camera's Bottom Hatch for Battery & SD Card

Opening the Camera’s Bottom Hatch for Battery & SD Card

This 3D-Printed mount sits higher, so I am able to open the bottom hatch for access to the Battery & SD Card.

Removing the SD Card While the Camera in on the Mount

Removing the SD Card While the Camera in on the Mount

Access to the SD Card without removing the camera from the mount keeps everything in position if I wish to remove the SD Card and review videos on my computer.

Removing Battery While Camera in on the Mount

Removing Battery While Camera in on the Mount

When taking Time-Lapse Videos over many days I don’t want the camera to move but I might have to take out the battery to charge it.

Putting the SD Card into the Canon Digital Camera on Mount

Putting the SD Card into the Canon Digital Camera on Mount

I have several different areas in the workshop to attach the mount’s tubing.

Click Here for View YouTube Video of Camera Mount

Click Photo to See Video of the 3D-Printed Mount

Click Photo to See Video of the 3D-Printed Mount

The Audio Narration on the Video starts about 1 minute into the Video ~ The first minute of the video shows the SolidWorks 3D-Model.

Nuts & Bolts Fit into Hex Shape Holes for Tightening the Parts

Nuts & Bolts Fit into Hex Shape Holes for Tightening the Parts

 

Once Angle is Set I Don't Have to Move it to Re-Charge Battery

Once Angle is Set I Don’t Have to Move it to Re-Charge Battery

SolidWorks makes it easy to make these parts and convert them into 3D printing .STL files and quickly 3D print on the AFINIA H-480 3D-Printer.

SolidWorks CAD Concept Model of the 3D-Printed Mount

SolidWorks CAD Concept Model of the 3D-Printed Mount

I added the SolidWorks CAD Files & .STL 3D-Printing files to GrabCAD.com

Click Here to View and/or Download the .STL Files on GrabCAD

SolidWorks Files and .STL Files for 3D-Printing are on GrabCAD.com

SolidWorks Files and .STL Files for 3D-Printing are on GrabCAD.com

Upper and Lower 3D-Printed Tubing Mount Items

Upper and Lower 3D-Printed Tubing Mount Items

Here are some images of the Lower Tubing Adjustment Clamp Mount …

Lower 3D-Printed Clamp Mount to Adjust the Thin Tubing Up & Down

Lower 3D-Printed Clamp Mount to Adjust the Thin Tubing Up & Down

Great use for those old Aluminum Curtain Rods that were going in the Trash!

… CHEERS!!!

.   .   .   .

 

 

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3D Printed Tripod Camera Mount

3D-Printed Camera Mount for Use on a Smith-Victor RS8 Tripod

3D-Printed Camera Mount for Use on a Smith-Victor RS8 Tripod

This Project is a 3D-Printed Camera Mount for use on a SV-RS8 Light Stand.

~ The 3D-Printing . STL Files can be found at GrabCAD.com  ~

Battery & SD Card Slot in the Bottom of a Canon PowerShot SD1100IS Camera

Battery & SD Card Slot in the Bottom of a Canon PowerShot SD1100IS Camera

I use an older Canon PowerShot SD1100IS to take Time-Lapse Videos of my 3D-Printing projects and wanted to have the ablity to remove/insert the SD Card & Battery without having to remove the Camera from the Tripod.

Using the Old Tripod to Take Photographs of the 3D-Printing Table

Using the Old Tripod to Take Photographs of the 3D-Printing Table

When I use the older Tripod with my small Canon Digital Camera the mount blocks access to the SD Card & Battery on the bottom of the Camera.

The SD Card & Battery are Trapped by the Tripod Mount

The SD Card & Battery are Trapped by the Tripod Mount

Planning on 3D-Printing a modified mount for my old tripod; however, I fixed a Smith-Victor RS8 Aluminum Light Stand for an individual and he has not gotten back to me, so while I have the Tripod decided to make a mount for it …

At $39.95 the SV-RS8 Stand is a Good Price for an 8ft Tripod

At $39.95 the SV-RS8 Stand is a Good Price for an 8ft Tripod

I previously drew the RS8 Stand into SolidWorks, so already had it available for designing a 3D-Printed Tripod mount with access to the SD Card area.

SolidWorks CAD Model for the Smith-Victor RS8 Light Stand

3D-Printed Camera Mount Parts Shown in SolidWorks CAD Software

3D-Printed Camera Mount Parts Shown in SolidWorks CAD Software

Designed the mount to use press-in #6 Nuts & Bolts to hold parts together …

SolidWorks CAD Rendering Showing Different Views of the RS8 Tripod Mount

SolidWorks CAD Rendering Showing Different Views of the RS8 Tripod Mount

When done had a camera mount that can adjust & tighten as needed …

The Finished 3D-Printed Camera Mount on the SV-RS8 Tripod

The Finished 3D-Printed Camera Mount on the SV-RS8 Tripod

The 3D-Printed Camera mount also allows me to open the bottom cover and remove/insert both the SD Card and the Camera’s Battery …

I Can Now Open the Cover for the SD Card & Battery

I Can Now Open the Cover for the SD Card & Battery

Now if the battery gets low and needs charging, or if I wish to pre-view the SD Card images on my computer, I can leave the camera in place …

Can Remove or Install the Battery & SD Card with Camera on Tripod

Can Remove or Install the Battery & SD Card with Camera on Tripod

The mount also works with my SONY camera when recording Hi-Res Video.

Sony Camera for Hi-Res Video Also Fits on the 3D-Printed Camera Mount

Sony Camera for Hi-Res Video Also Fits on the 3D-Printed Camera Mount

The Smith-Victor RS8 Aluminum Light Stand goes up to 8ft tall, but uses much less room on the floor making it easier to work around when filming video …

Easier to Work Around the SV-RS8 Tripod when Recording Video

Easier to Work Around the SV-RS8 Tripod when Recording Video

The 3D-Printed Tripod Camera mount is nothing fancy but works for what I need and the 3D-Printing .STL files can be found on GrabCAD.com

SolidWorks CAD Model for the 3D-Printed Camera Mount

Now the only step left is to order a $40 Smith-Victor RS8 Aluminum Light Stand for myself so I can get this repaired one back to Chris.

Click Here to Review and/or Order the SV-RS8 Online

… CHEERS!!

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3D Printed Hole Measurement Inserts

3D-Printed Threaded Inserts to Measure Center-to-Center Hole Distances

3D-Printed Threaded Inserts to Measure Center-to-Center Hole Distances

As I have mentioned before ~ Sometimes simple items are the most helpful …

Close-Up View of the 3D-Printed Threaded Measurement Hole Inserts

Close-Up View of the 3D-Printed Threaded Measurement Hole Inserts

I use to work inside ships aligning & welding items, and if you have ever been inside a ship you know nothing is straight, level, or easy …

Example of What a Ship's Piping & Inner Metal Structure Might Look Like

Example of What a Ship’s Piping & Inner Metal Structure Might Look Like

Therefore, one needs to be able to mount ‘measurement items‘ in specific places and measure out from those areas to triangulate distances, etc.

Once Ya Know the Distances ~ You Can 'Jethro' Cipher Out Where to Put the Items

Once Ya Know the Distances ~ You Can ‘Jethro’ Cipher Out Where to Put the Items

Several years ago I machined some threaded & magnetic measurement inserts and decide to 3D-Print up several new ones for a current project …

3D-Printed Concept of the Hole Center Threaded Measuring Inserts

3D-Printed Concept of the Hole Center Threaded Measuring Inserts

3D Printing allowed me to design without having to worry about draft angles.

Measurement Inserts Line Up with the Center of the Hole

Measurement Inserts Line Up with the Center of the Hole

The design needed to allow for measuring holes from Center-to-Center …

SolidWorks CAD Software Allows Users to See Transparent Views

SolidWorks CAD Software Allows Users to See Transparent Views

Used several different standard size Machine Bolts as part of the design …

End of Tape Measure Locked into the Center of the Hole Location

End of Tape Measure Locked into the Center of the Hole Location

The Key to the design is one edge is perfectly aligned with the Center of the hole so that when the tape is pulled against that edge it aligns with the center of the hole for measuring Center-to-Center hole measurements.

Edge Lines up with Center of Hole

Edge Lines up with Center of Hole

The Measurement Inserts are also designed so they are exactly 1/2″ from any flat edge to the center of the hole being measured with the Tape …

Can Also Press the End of the Tape to the Side of the Threaded Insert

Can Also Press the End of the Tape to the Side of the Threaded Insert

Many times I will run a guide string to get a visual of where items are going to run through other structures for which I am designing my items to fit within …

There is also a Notch in the Front of the Insert for a Guide String

There is also a Notch in the Front of the Insert for a Guide String

The notch in the side of the insert holds the bottom of the string 1″ up from whatever the 3D-Printed inserts are mounted to …

1/2" Thread Version of the 3D Printed Measurement Inserts

1/2″ Thread Version of the 3D Printed Measurement Inserts

Also created a 1/2″ size version of the Hole Measurement Inserts which allows me to hand-turn in 1/2″x 13TPI All-Thread to secure the inserts to items …

Top and Bottom Views of the 1/2" Threaded Measurement Insert

Top and Bottom Views of the 1/2″ Threaded Measurement Insert

I used two 3D Printed parts and pressed in a 1/2″ Nut inside the unit …

1/2" Threaded Measurement Insert Bolted in the Hole

1/2″ Threaded Measurement Insert Bolted in the Hole

This 1/2″ Nut Version also has a Locking-Screw for the end tab of the Tape …

End of Tape Locked into Center-of-Hole Location

End of Tape Locked into Center-of-Hole Location

My AFINIA H-480 3D-Printer creates very accurate parts allowing the center hole measurement to line up very well with the 3D-printed insert edge ….

3D-Printing Resolution for the AFINIA H-480 is 0.20mm ( 0.0078″ )

Another Measurment Insert on Other End of Tape Showing 15.25"

Another Measurment Insert on Other End of Tape Showing 15.25″

Created a quick ( unedited ) Video talking about how I use these items …

Click on Image to View a VIDEO of the 3D-Printed Hole Measurement Inserts

Click on Image to View a VIDEO of the 3D-Printed Hole Measurement Inserts

I tend to go through a lot tape measures due to welding & dropping, so purchased a few extra of my favorite DeWALT DWHT33373L Tape Measures.

Extra DeWALT 33373 Tape Measures for Future Projects

Extra DeWALT 33373 Tape Measures for Future Projects

The next time I have the camera with me on a job-site, I will take some more photos of these Hole Measurement Inserts being used on a project.

UPDATE:

I was asked for more information about the Aluminum Metal Version …

SolidWorks CAD Software Aluminum Machined Version

SolidWorks CAD Software 1/4″ Machine Screw Aluminum Version

These are the dimensions I used to machined the Aluminum version.
( Started with 1″ Diameter Aluminum Round Stock )

Dimensions Used to Machined the 1/4" Machine Screw Version

Dimensions Used to Machined the 1/4″ Machine Screw Version

Threaded Transfer Screw Sets work great for short distances …

Screw Transfer Set for 1/4"-20TPI Threaded Holes

Screw Transfer Set for 1/4″-20TPI  Threaded Holes

 

… CHEERS!!

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Aluminum Cast Drill Press Knobs

Aluminum Cast Replacement Knobs for the Drill Press

Aluminum Cast Replacement Knobs for the Drill Press

I feel if you have a Metal Lathe, a MIG & TIG Welding Machine, a Milling Machine, and a few friends~ Then many of the rest of one’s Metalworking Shop Tools can be made from scratch.

… I’ll now add a 3D-Printer to the list of those initial tools …

AFINIA 3D-Printer with some Patterns I printed for SuperDave' Project

AFINIA 3D-Printer with some Patterns I printed for SuperDave’ Project

Also ~ One can buy inexpensive and/or used equipment and repair them as new.

Everything on this website is Just-for-Fun, so the process of these projects may not be the most logical because the point is to experience something new and have some fun doing it.

3 Broken Plastic Knobs on My Inexpensive Drill Press

3 Broken Plastic Knobs on My Inexpensive Drill Press

After re-machining and a few simple upgrades, I now really like my 16 Speed Floor Harbor-Freight Drill Press.

The only issues left to fix on it are a damaged top pulley cover latch and the three broken plastic handle knobs.

Close-Up of Broken Plastic Knob Off My Drill Press

Close-Up of the Broken Plastic Knob Off My Drill Press

Over time all 3 of the plastic knobs have cracked and do not tighten on the threaded handles, so I decided to make a 3D-Printed pattern for new  knobs …

SolidWorks CAD Model of the Split-Pattern for the Replacement Knobs

SolidWorks CAD Model of the Split-Pattern for the Replacement Knobs

No special reason for the unusual shape … Just having fun!!  😜

Unusual Shape for the Replacement Drill-Press Aluminum Knobs

Unusual Shape for the Replacement Drill-Press Aluminum Knobs

Once I had a design, then created the Split-Pattern’s .STL files & 3D-Printed …

Knob Split-Pattern .STL File Opened in AFINIA's 3D-Printing Software

Knob Split-Pattern .STL File Opened in AFINIA’s 3D-Printing Software

At the same time, I made several 3D-Printed patterns for SuperDave

3D-Printed Patterns Created for Aluminum Metal Casting

3D-Printed Patterns Created for Aluminum Metal Casting

Mailed the 3D-Printed patterns over to SuperDave for him to cast …

SuperDave’s Metal Casting Sand Flask Mold to Pour in Aluminum

SuperDave was nice enough to send some photos of the casting process …

Close-Up of the Knob's Shape in a Sand Mold

Close-Up of the Knob’s Shape in a Sand Mold

Didn’t sand the knob pattern’s notches because did not mind them rough …

Finished Metal Casting of Knob by SuperDave

Finished Metal Casting of Knob by SuperDave

A few days later SuperDave mailed the Aluminum castings back to me …

He left some as they came out of the sand, so I could see how they were cast.

Group of Metal Casting SuperDave Sent to Me from 3D-Printed Patterns

Group of Metal Castings SuperDave Sent to Me made from 3D-Printed Patterns

Next step was to clean up the Replacement Aluminum Knob castings …

Cleaning the Aluminum Drill Press Replacement Knob Castings

Cleaning the Aluminum Drill Press Replacement Knob Castings

Didn’t buff them too much, just enough to make sure no sharp areas …

Ground and Lightly Buffed the Knobs Sharp Areas

Ground and Lightly Buffed the Knobs Sharp Areas

Clamped down a Hand-Held Mini Belt Sander to help with the clean-up …

Hand Held Mini Belt Sander for Grinding Off Castings

Hand Held Mini Belt Sander for Grinding Off Castings

After the quick clean-up ~ Tapped metric threads into the Aluminum Knobs …

Using a Metric M10 x 1.5 Tap to Add Threads to the Aluminum Knob

Using a Metric M10 x 1.5 Tap to Add Threads to the Aluminum Knob

Once done … Screwed on the Replacement Aluminum Cast Knobs ~ Yay!!

New Aluminum Cast Replacement Knobs on the Drill Press

New Aluminum Cast Replacement Knobs on the Drill Press

I could have purchased new knobs and quickly put them on the Drill-Press …

But … 3D-Printing the Patterns & Aluminum Casting Knobs made it fun!!  😎

Another View of the Old Drill-Press with New Aluminum Knobs

Another View of the Old Drill-Press with New Aluminum Knobs

UPDATE …

At the beginning of this post you can see there is another knob pattern …

3D-Printed Patterns for a 'HURST' Type Shift Knob

3D-Printed Patterns for a ‘HURST’ Type Shift Knob

This is a Shift Knob for my 1999 Jeep … Also made an additional version of the pattern with lettering on it for SuperDave to cast for his projects …

One Half of the 'Hurst' Type Shift Knob on the 3D Printer

One Half of the ‘Hurst’ Type Shift Knob on the 3D Printer

SolidWorks CAD Software allowed me to add a ‘Draft Angle’ to the lettering to make it easier to pull the pattern out of the sand and cast the letters …

Adding Lettering to the Pattern with a 'Draft Angle' to Pull Out of the Sand

Adding Lettering to the Pattern with a ‘Draft Angle’ to Pull Out of the Sand

I based the metal casting patterns off of the old ‘Hurst’ Type Shift Knob …

Jeep Shift Knob Pattern BEFORE and AFTER Buffing

Jeep Shift Knob Pattern BEFORE and AFTER Buffing

Additional Views of the Hurst Type Shift Knob for the Jeep

Additional Views of the Hurst Type Shift Knob for the Jeep

Had to Leave a Few Scratches on the Jeep Knob ~ It's a Jeep Rule :-)

Had to Leave a Few Scratches on the Jeep Knob ~ It’s a Jeep Rule  🙂

I didn’t buff the Shift Knob too much ~ Cause it’s for a JEEP!!!  😜

Once Again ~ Thank You SuperDave!!

Click Here for More ‘METAL CASTING’ items

… CHEERS!!

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