Need a part for your Cobra?

[Cobrabill]

Just "beam up" to the Enterprsie and pop it in the replicator.

http://widgets.nbc.com/o/47f1317f105...a4377d3bfd6c81

[Ron61]

Bill,

That is really amazing. Now if I can just figure out how to change bodies with Jay Leno. Or get to use that machine for a short time with some $100 dollar bills. Good thing it doesn't duplicate people.

Ron

[Doug I]

That technology isn't that new. We first came across this ~3 years ago. In our business we model in 4D civil, structural, mechanical and architectural projects to then develop conventional drawings for construction. These 3D printers allow us to print the models in real life for concept, presentation or development.

Heat fused ABS plastic is the latest medium for high strength applications - as in that functional wrench. Next phase is laser fused aluminum oxides that will by-pass the casting stage in going from computer model to machined product.

Doug

[Doug I]

umm actually Ron ......

one of the applications of the 3D printer and the modeling software is the ability to take the MRI or CT scan data and print it. The more conventional printing mediums are available currently in 256 colors and are amply strong enough to be handled. The largest printers on the market now could print a fully detailed (well at 1200dpi) body in 3 pieces that when glued together you would be hard pressed to see the joints

[Ron61]

Doug,

Not trying to start an argument but just a question. I can see the advantage of your new technology, but can you absolutely guarantee that the new part or whatever you are making is going to work and fit if it requires exact tolerances? I have never seen a computer that the operator or the machine can't make a mistake once in a while and in this case it only has to be one so small they you couldn't see it with the eye if you are casting precision parts for something. I do think going straight to the part wold be great as it should, but probably won't, cut the cost some.

Ron

[csx wnab]

that is amazing.

[Ron61]

Doug,

Thanks for the answer. It is to bad they can't use this technology to replace broken and crushed bones and such. But who knows, maybe someday. Science and technology marches on. Some will be great and some will be not so great but we can't just stop and sit still.

Ron

[Doug I]

Ron - good question. Thre easy answer is 'yes' The more involved answer is ..still .... yes

In the original computer model we work with actual dimensions and we can set the collision limits to whatever we want/need. This really helps in our main line or work which is Civil and Structural design and Project Management. We build up a model of the building from the individual pieces, down to the nuts and bolts. If they don't fit in the model then they won't fit when built. We also model the MEP (mechanical, electrical and plumbing) systems which will show any conflict or collision with other elements. We can set that collision tolerance to any number to ensure that, say, a gas line is never closer than 'x' feet to an electrical main, or 0.001" for gears .

From that model we can not only make a paper drawing for construction but we can produce a list of components - this many bolts of this diameter/grade/length and that d/g/l etc etc. With modeling in the 4th dimension (time) we can show you a model of the building at any date of construction. That also lets us tweak the schedule to save a few days here and there.

Using as an example that D-valve in the video the first problem in modeling the piece is that the scan is of a broken or worn part, so the model with replicate that. We'd then take measurements of where the part fits to make sure the scan was ok if it was made from stuck together broken pieces. The printed ABS piece would then be tested in place and machined so that it fitted. The model could then be tweaked, new piece printed, then cast, then machined to fit. A competent tool-maker would find no problem with that at all.

There'll always be mistakes and screw-ups but with the electronic models they are easy to change, and re-printing a prototype is easy. These changes are far easier to make and fix compared to the original method of wooden models of the part being cast. Cast parts are always made with extra material so they can be machined down to the dimensions required. The first piece machined on the mill would be checked for dimensions and fit, then the remaining 999 copies can be done.

[wtm442]

That is some cool stuff. Of course, when I need an extremely rare part that I cannot find, I always check with Kale Auto first.

http://kalecoauto.com/

[Silverback51]

Stereolithography is really neat stuff to work with. We have been using it to a considerable extent on the project I'm currently working on.

Tolerance wise we are holding +/- .005, but it's just like machine work. The closer the tolerance required, the more it costs.

They are also making parts out of scintered (excuse me, I'm an engineer and cannot spell worth crap ) metal, which means depending on their use, do not require any machine work to be used.

We started using the stereolithography process in my area about 12 years ago, so it's been around for a while. Like most things, it's now cheap enough that it's used more.

[Ron61]

Doug,

It sounds as if you have the technology down to a very good point. And I was wondering about the broken part where they glued it back together if it was a very tight fit, would the break case a problem with the finished cast part, but now I can see how you would work it and it all makes sense. And with the tolerances that you can set, everything should work great. Sure beats the old slide rule and drawing paper method. I remember when I started in computers, to do any graphics I had to have a graph sheet that had the coordinates of the screen and I would then put marks where I wanted the lines. After that to get it onto the computer I had to go in and type in each point and it would then light a pixel there. Once I saw how it was going to look, I could have it start putting in the lines to connect the dots. Boy, am I ever happy that I don't have to try to keep up with all of the new technology now.

Ron

[Silverback51]

Originally Posted by Ron61

Doug,

It sounds as if you have the technology down to a very good point. And I was wondering about the broken part where they glued it back together if it was a very tight fit, would the break case a problem with the finished cast part, but now I can see how you would work it and it all makes sense. And with the tolerances that you can set, everything should work great. Sure beats the old slide rule and drawing paper method. I remember when I started in computers, to do any graphics I had to have a graph sheet that had the coordinates of the screen and I would then put marks where I wanted the lines. After that to get it onto the computer I had to go in and type in each point and it would then light a pixel there. Once I saw how it was going to look, I could have it start putting in the lines to connect the dots. Boy, am I ever happy that I don't have to try to keep up with all of the new technology now.

Ron

You can do surface smoothing for the breaks and surface irregularities

[Doug I]

Our entire office spends 1 week a year in fully time training on the software and it's applications. In that week we also spend a lot of time with the technology vendors getting to grips with the hardware.

All through the year we'll spend additional time in training and practice, so it isn't easy to to keep up, or lead the curve, on knowledge and technology but somehow we do ... mostly Now is a better time though than a few years ago - now the hardware can keep up with the software.

[Bryan Wilson]

If it can replicate a part so accurately wouldn't you just end up with a brand new worn out part.

[Ron61]

Bryan,

Now that was worth the read.

Ron

[Doug I]

maybe we can make FE parts then

[trularin]

Interesting video.

[Ron61]

Doug,

The FE parts would have to be very carefully crafted to make sure they leak the proper amount of oil after a couple of days of running.

Ron

[tcrist]

Cobrabill,
Interesting,
I wonder how large of a part that machine will actually scan?
Terry

[Ron61]

Terry,

I was kind of wondering the same thing but I am sure they will be making them for larger parts as they advance the technology. When they get one that can do a complete car, would one of you original owners let them do one for me?

Ron