3D printing your washer parts

[ovrphil]

For some parts, you can just 3D print them...and it's only going to become more possible, cheaper and easier. Maybe it's the next big thing, since the personal computer(?).

http://www.askmen.com/entertainment/galleries/top-50-things-you-can-make-with-a-3d-printer-15.html

 

[whirlcool]

Can you imagine being able to "print" a multimatic oil bellows?

I think that eventually the manufacturers of these printers will have to make a wide variety of different printing "stock" for people to use to get the desired durability of goods.

 

[Unimatic1140]

I've been watching this technology for years

Can you imagine being able to "print" a multimatic oil bellows?

By 2020 I completely expect to be able to do that, but with Silicone rubber as opposed to Neoprene which is a much more reliable rubber.

Lint Chaser Rings, Westinghouse Laundromat Door Boots, ABC-O-Matic Agitator Wings, Philco Agitator Disks, dryer door seals, etc, etc, etc.

With a 3D scanner you will be able to make a perfect copy the part in three dimensions, adjust it with proper software and print out new rubber parts. This technology will keep our machines in tip top shape for the rest of our lives.

Once this technology becomes more affordable I totally plan on diving in head first and create a ton of vintage replacement parts.

 

[kb0nes]

3D printing technology is indeed amazing, and have improved in leaps and bounds over the past couple years. I still find it humorous that the attitude is that it can simply replicate anything.

There are a couple major issues with the idea of simply replicating NLA parts.

The first and most significant problem is how do you get a 3D solid computer model of the part you need to replicate? Yes there are optical scanning CMM's (coordinate measuring machine) that look at the part and output a file, but these are EXPENSIVE. One could measure using simple inspection tools also and then learn a 3D CAD program also, again not trivial both from learning curve and cost.

The second issue is that the range of choices for the material the part can be made from is fairly limited at this time. Also properties of the printed material aren't all that great, being that the part is made layer by layer the plastic doesn't have fully homogeneous internal structure. In other words its not all that strong, although both these issues are something that is improving with time.

I manage a small short run and prototype CNC machine shop. We have a few customers that use 3D printing technology for prototyping. Only one customer uses 3D printing for parts that actually go to an end user. These are hearing aid cases which don't require any great strength or durability. In this case 3D printing is perfect and it takes the moldmaking and casting out of the picture, greatly streamlining production.

For any parts that require durability machining from solid stock is still the way to go. This allows the part to be made from practically any material, not just a few printable polymers. Besides if you get to the point where you have a 3D model of the part, a machine shop could easily replicate the part too.

One neat resource for machined parts is eMachineshop (even if they are a direct competitor to our shop). This is an online interface to a prototype machineshop. You download their CAD software, draw your part then upload and they make it. Pretty spiffy!

http://www.emachineshop.com/

 

[jeffg]

"The first and most significant problem is how do you get a 3D solid computer model of the part you need to replicate? Yes there are optical scanning CMM's (coordinate measuring machine) that look at the part and output a file, but these are EXPENSIVE."

3D scanners/model/file generators are down to $499 and I think prices for them will nosedive when major scanner/printer manufacturers get onboard. I think the scanners will eventually be incorporated into the printers. Also the numbers of available filaments seem to be growing fast, we saw everything from steel to sugar (for making candy believe it or not) for these printers.[this post was last edited: 1/12/2014-14:07]

http://investorplace.com/2014/01/ces-2014-cool-new-gadgets/3/

 

[kb0nes]

The accuracy of this unit is?? I couldn't find any thing on their site.

I'd wager it's no where good enough to make a mechanical part that will work. Unless you have true accuracy to .0001" it really isn't good enough. It would probably make a dandy model of a chess piece though.

I agree that technology is RAPIDLY increasing, but we aren't there yet.

 

[jeffg]

I agree there's a long way to go. High resolution 3D object scans and files are being compiled in databases (e.g. see Thingiverse.com), so one is limited not by one's own model of an object, but only by the best models anyone has ever taken and shared of it. 3D printers themselves have no problem with reproducing this accuracy.

 

[sudsmaster]

A couple more comments about the limitations of 3D printing:

Speed: It can take hours to produce a part. Sure, the machines can get faster, but there is a limit to how fast they can get. Think about old time plotters (with pens) and you get an idea of what's involved. Multiply that times the many layers the 3d object will require. And 3D printing, because of the speed, won't be used for mass production any time soon.

Materials: Various plastics are available for smaller hobby size printers. But metals are still rare, and the province of industrial type machines. Think about it: how hot does the metal need to get to melt and form a layer? Not exactly something you'd want in your den.

Finish: All the 3d parts I've seen have a pretty crappy surface finish. It's a result of the finite size of the drops of molten material that is being layered. So if you need a smooth surface (like for a bearing surface) you'll probably still want to use some sort of subtractive tooling (reamer, mill) to get that.

Size: Hobby size 3D printers may only be capable of building a object about the size of a pack of cards. Bigger means more expensive. Not a deal breaker, unless the object you want to make is bigger than the capability of your printer.

 

[petek]

Of all the new techie stuff shown at that CES show etc. 3D modelling is the only thing that really catches my attention .
It's definitely going to change things. Even if there isn't an affordable high enough quality home unit for some things, larger items etc.. there's sure to be somewhere you can go and have it done in the meantime.
Imagine if you needed to get a prosthetic hand arm,foot,leg. They could just scan the opposite one and make a virtual mirror copy right down to the pores and skin color.

 

[jeffg]

I think these printers will eventually democratize production the same way the internet democratized communication.

 

[tolivac]

For items that need strength-this could be done by not "printing" the part but routing,carving,or machining it with a computer controlled router,laser cutter,or even waterjet cutter type devices-and the speed would be faster.Sort of fascinated by these devices more so than the "printing" type ones.Yes,we have a ways to go-but will be with use before you know it.At one machine shop near Wilson NC, watched a Toshiba laser cutter cutting out roof panels for John Deere harvesters-they could stack the metal panels and cut several at once-really cool!!and the cut edges didn't require any further finishing.No deburring or anything-just paint the roof panels JD Green and good to go!That machine shop also made and refurbished parts for the nearby Michlen Tire plant.Lots of really large steel rollers waiting to be refurbished!The shop also has a waterjet cutter for doing all types of materials-the pump on that thing was large-75Hp motor and could delivor up to 50,000PSI.The jet could work with water only or be injected with abrasives.

 

[circlew]

I know what some of you guys will be making if you get such a machine!

 

[kb0nes]

Abrasive Waterjet

Slightly off topic, but Rex mentioned Waterjet cutting.

Here is a scrap slug of 2024 aluminum I had laying about. It's 5" thick plate that we had a 7" dia hole cut through. It was more economical to let the Waterjet then mechanical cutting and we get to salvage an $80 piece of aluminum to use for something else.

If you look closely down near the bottom you can see the kerf roughness caused by the jet lagging the cut. Also at the 10 o'clock point you can see the spot they started the cut at.

 

[tolivac]

Phil: thats an impressive cut you made with your waterjet machine-imagine the cut quality though,if you tried to cut that peice with a saw-like a bandsaw.It would most likely be rougher.We can also imagine if you tried to "print" that slug peice!!!Shows there are some things that a 3D printer can't do.So we have to go to man controlled or computer controlled cutting machines to do the jobs.So we still need machinists!!!Neat work!!!

 

[kb0nes]

3D Scanning Webinar

I just watched this 3D scanning Webinar which deals with scanning and reverse engineering parts, just what we need for part reproduction. Its about an hour long and perhaps a bit in depth but interesting none the less.

http://www2.faro.com/site/resources/share/2179

Faro is a company that has been around for a while now and they started out making Arm style Coordinate Measuring Machines (CMM) that worked via contact probing. They have since added optical scanners and with the use of a LASER they can now scan a 3D point cloud into the computer. The Faro ScanArm states an accuracy of +/-.0014 which is getting there, certainly close enough for most parts. Not close enough for bearings or tight tolerance fits though. Really a measuring system needs to be 10x more accurate then the tolerance you are shooting for.

For the record these Faro ScanArms start at about $40,000. Perhaps Jay Leno has one, but its going to be a while till the rest of us can afford something that can simply reverse engineer a mechanical part.

It will be interesting when the consumer grade scanning cameras and software develops a bit more. For overall part shapes they will be adequate and the tight tolerances could be measured manually and added into the model.

 

[tolivac]

I would think the Faro Scan Arm machine would be within "reach" of a good or large machine shop,though,not for an individual person or hobbyist-yes guess Mr. Leno could afford his own-but what would he use it for?

 

[kb0nes]

The reason I used Leno as an example is that there is a video on YouTube where he had a automotive part scanned and printed. They used a Faro arm scanner to digitize the parts. The video seemed to be an infomercial for a couple companies. Knowing Jays garage and his restorations I have a feeling he may own one of these scanners...

Of the automotive parts they 3D printed in the video, it sounds like they were all for mock up only, the parts were ultimately cast or machined from metal.

Here is the video, kinda cool to see the scanner in action.

 

[tolivac]

Mr Leno did a really good demo of the Faro scanner device-We could use it here for making not car and car motor parts---but transmitter parts-like Mr Lenos cars the parts are unobtanium.This device could help in making the parts.Nice ideas.Maybe I should watch the Jay Leno show more often-thought he would have someone do those things for him-but admire Mr Leno--he does it himself!GOOD FOR HIM!!The clip shows some good shots of Mr Lenos shop-really nice!!!He is not an ordinary hobbyist!