Scantlings

now that I'm working on the final 5% of my printer designs (which is pretty much an asymptote), I'm starting to work on some quality samples.

Here are some of the rough models. I am tuning the software to improve quality on these things. It's quite a learning process.

Here's a screen shot of the process. The software has to 'slice' the model into layers. Essentially, it's as though you layered hundreds of 2D printed sections on top of one another. The software handles all the math for the shape, thickness of perimeters, fill, etc.

I'm now about 95% satisfied with this. It's been quite a challenge. It's quite interesting to see how complex a sailboat is when 3D printing. There are so many subtleties to the geometry and it can really highlight the shortcomings of the entire process. Consider that FDM printers like this print in layers, there is a limit to how small the layer can be. Generally, I print at 200 microns. 100 microns is considered a pretty fine resolution. With my current setup, I can print at 50 microns. With a smaller nozzle I could cut that in half. The problem is, those high resolutions come at a cost. At 100 microns, this model takes over 20 hours to print. At 25 microns it's realistic to believe that it could take 2 days or more.

That said, it's a fascinating process and pretty much hands off once you start. It's a good test of the reliability of a printer.

It took a great deal of effort to dial in the settings to get this to print. Each hull took about 16 hours to print. I also broke down the model into components and just printed the problem areas. Eventually, I was able to accomplish the quality you see above.

I'm currently printing another hull at 100 microns and some tweaks to the support settings. The biggest problem area is the stern sections as they rise gradually from the waterline. The plastic does not have anything to support it when it's extruded so sacrificial supports need to be printed in order to hold up those sections.

I haven't been keeping track of how many hours this has taken, but I've been at it for over a week.

I'm a big fan of iterative design - fail faster.

And this little guy is the first iteration I printed over 2 years ago on my crappy, wooden 3D printer.

It actually doesn't look all that bad. I'm very impressed with the pillars between the windows.

None of this should be a reflection on the quality of the printer other than the fact that it is capable of some pretty high quality prints. Getting things setup was the biggest challenge.

Rick. That is seriously cool. Keep it up and keep posting your projects. Very, very cool.

This is great fun to watch

what the heck is it???

Very cool!
One of the Hylas owners couldn’t find a replacement fuel fill cap so be printed one.

I think you just disrupted the half-hull model industry. Instead of paying someone to build one for $400-500 bucks, you could probably print one for less than half of that.

Ajax,

Depends on the value of your time!

When I was a kid my father was friends with a guy who built models of old sailing ships for the Smithsonian. Last time I looked, the models were still on display.
He was a butcher by trade and had massive hands, but he made models where even the windlass worked. He estimated 5,000 hours per model, or about $1 an hour.

3D printing is nice for visualization. But if you want it to look really fantastic, it takes about as much time as carving it. In 5 years that may not be the case. In 10 years, that will definitely not be the case.

Soñadora wrote:3D printing is nice for visualization. But if you want it to look really fantastic, it takes about as much time as carving it. In 5 years that may not be the case. In 10 years, that will definitely not be the case.

Neat. I want improvement in the materials used. Many of us want to print parts that require significant strength.

Ajax wrote:

Soñadora wrote:3D printing is nice for visualization. But if you want it to look really fantastic, it takes about as much time as carving it. In 5 years that may not be the case. In 10 years, that will definitely not be the case.

Neat. I want improvement in the materials used. Many of us want to print parts that require significant strength.

In my opinion, the race is on with regards to strength between metal and plastic 3D printing. Metal "printing" is done via sintering which results in a part very much like a casting. OTOH, plastic printing is getting stronger and stronger thanks to ingenious ways the layers are being applied and the types of materials being developed, namely CF and nylon. I honestly believe we will see plastic parts that will surpass the strength of metal. Metal printing is very expensive requiring enormous amounts of power.

Soñadora wrote:

Ajax wrote:

Soñadora wrote:3D printing is nice for visualization. But if you want it to look really fantastic, it takes about as much time as carving it. In 5 years that may not be the case. In 10 years, that will definitely not be the case.

Neat. I want improvement in the materials used. Many of us want to print parts that require significant strength.

In my opinion, the race is on with regards to strength between metal and plastic 3D printing. Metal "printing" is done via sintering which results in a part very much like a casting. OTOH, plastic printing is getting stronger and stronger thanks to ingenious ways the layers are being applied and the types of materials being developed, namely CF and nylon. I honestly believe we will see plastic parts that will surpass the strength of metal. Metal printing is very expensive requiring enormous amounts of power.

Sons,

Tend to agree but printing will never completely replace machining and forging for fatigue critical items. Sintering, as you point out is basically casting with stress risers between layers. Getting better all the time but, to quote our chief scientist, still just artistic “weld melt” from a physical properties standpoint.

“Plastics”, on the other hand, are seeing lots of progress in higher strength applications and folks are starting to play with hybrids that will melt and print as thermoplastics but cure in a similar manner to thermosets. Add in the carbon or other high strength fillers and use a resin with a higher transition temp and you are getting there in strength. Still have the Z axis limitations in cross linking layers but that’s being worked hard.

You are doing some impressive stuff. Keep posting it.

LarryHoward wrote:

Soñadora wrote:

Ajax wrote:

Soñadora wrote:3D printing is nice for visualization. But if you want it to look really fantastic, it takes about as much time as carving it. In 5 years that may not be the case. In 10 years, that will definitely not be the case.

Neat. I want improvement in the materials used. Many of us want to print parts that require significant strength.

In my opinion, the race is on with regards to strength between metal and plastic 3D printing. Metal "printing" is done via sintering which results in a part very much like a casting. OTOH, plastic printing is getting stronger and stronger thanks to ingenious ways the layers are being applied and the types of materials being developed, namely CF and nylon. I honestly believe we will see plastic parts that will surpass the strength of metal. Metal printing is very expensive requiring enormous amounts of power.

Sons,

Tend to agree but printing will never completely replace machining and forging for fatigue critical items. Sintering, as you point out is basically casting with stress risers between layers. Getting better all the time but, to quote our chief scientist, still just artistic “weld melt” from a physical properties standpoint.

“Plastics”, on the other hand, are seeing lots of progress in higher strength applications and folks are starting to play with hybrids that will melt and print as thermoplastics but cure in a similar manner to thermosets. Add in the carbon or other high strength fillers and use a resin with a higher transition temp and you are getting there in strength. Still have the Z axis limitations in cross linking layers but that’s being worked hard.

You are doing some impressive stuff. Keep posting it.

Agree that machining/forging are inherently stronger. My point was directed at sintering vs. 3D printing. That said, what 3D printed plastic provides is a new way to design. It may be possible to design a plastic part that would be stronger than a machined or forged part by designing it in such a way that it could never be machined. There will always be metal parts. Metal is not going to disappear. It is one of the most recyclable materials available (though recycling methods are costly). But I can see a large portion of the metal footprint in products being replaced with printed parts.

The solution to z-axis issues is to print in true 3D. Personally, I would consider current 3D printing methods to be more like 2 1/2 D. What we should see soon is multi axis print heads printing on top of a 'mandrel' or pattern of some kind. That's how I'm envisioning it, anyway. The pattern could be printed 2 1/2 D and the multi-axis print head would print on top of that. The patter would be removed chemically or physically. Most likely chemically printed with something like PVA.

Glad you guys are enjoying this

Hoping to be done with my Saturn V soon.

Guys like RIck are a big factor in why I'm confident in this country for the long run.

Orestes Munn wrote:Guys like RIck are a big factor in why I'm confident in this country for the long run.

me too