3D Printers
Frank Sergent
I changed the subject line here because this is shop talk and a little off
topic but is in response to LJ’s question and something I am still passionate
about.
I don’t believe a run of the mill (FDM) 3D printer that squirts molten
plastic out of a heated nozzle can work for this. The features on the couplers
are very small and they have to be produced accurately. Think about the diameter
of the little hinge pin that the knuckle swings on. Its diameter is 0.0130
inches. My original 3D wax printer acquired in 2009 (for about $17k and probably
never actually paid for itself) had a drop size of 0.0010” meaning it could
squirt a single drop of wax 0.0010” in diameter. That was good enough to form an
HO scale coupler than would work. My current printer acquired in 2013 (for about
$24k that paid for itself in 3 years) has a “voxel size” of 0.0016”. That works
too. My newest not yet in service printer acquired just this week (for less than
$1000) has a voxel size of 0.0019” which I think will be fine as well. What’s
the smallest drop of plastic a typical 3D printer can squirt out? About 0.01
inches in diameter which just doesn’t cut it. Its not the right tool for the
job.
I put the pay off times in there for anybody that is thinking about jumping
in. Those are based on profit from items sold that were 3D printed. They don’t
take into account the fact that I sell many more diecast couplers just because I
can offer the specialty couplers. You can see that my new printer will pay for
itself in less than 2 months at the same rate.
For this work you need a printer targeted at the jewelry and dental
markets. There have been some major advances that have occurred here recently
that has allowed the price of these very high resolution printers to drop like a
rock. Older designs use a UV laser or projector (like the one in a conference
room) to selectively solidify liquid resin one layer at time to create a 3D
object. The laser hardens one pixel at a time and is slower because the laser
has to “draw” each layer. The projector projects the complete image for the
layer at once, so its faster. Newer designs are actually much simpler. Rip the
LCD display off your fancy new phone and put a few UV LED’s behind it. Now the
pattern of UV light image that gets through the LCD can be directed at some UV
sensitive resin. Add a computer to control the image on the LCD and some
mechanics to advance the 3D object a little after each layer hardens and you
have the world’s cheapest 3D printer. Fancy phones with fancy super high
resolution screens have enabled this technology leap in 3D printers. As long as
what you need to print is smaller than the display on typical phone, your all
set. Imagine what happens if you have a 11” 4K LCD for a tablet computer. Hmmm.
Most HO locomotives and rolling stock many structures are small enough to fit in
that area. Trackwork components could fit in that area too if you don’t mind
plastic track (Unprototypical shiny nickel silver railheads on passing tracks
and sidings irk me anyway – why is that acceptable – dead rail is coming). See
where this is all going. These are exciting times in the model railroading world
and things are about to get crazy.
Also regarding 3D CAD. Check out Fusion 360. Free for a year for hobbyist
and small businesses. I have historically used Solidworks, but Fusion 360 is
about to eat its lunch. Fusion 360 plus a new ~$500 printer and a website can
make you a model railroad entrepreneur. You still need to be able to turn those
plastic parts into metal to make couplers, but maybe you have other ideas.
Finally in my opinion, the plastic parts created by any of these fancy new
printers I’ve described is hard and too brittle for items that will take
constant abuse like a coupler.
Frank
From: ljcasey1
Sent: Wednesday, July 11, 2018 2:33 PM
Subject: Re: [Sergent Engineering] Sergent Engineering
Couplers interesting question regarding the 3d printing. what is
the problem so far with people printing in 3d? tolerance, or
material strength. I know there are some metal filaments
available with different metal types in 'suspension' with the PLA or
whatever. Has that been tried? perhaps that has no more
inherent strength than straight PLA or whatever. I also doubt it
allows any finer tolerances. Just wondering aloud.
I have a mostly put together home 3d printer, but haven't learned any CAD
yet. I would assume that a typical home 3d printer has insufficient
precision to allow the tolerances needed amongst the parts, but would love to
hear what you(Mr Sergent) has to say on the issue.
thanks,
LJ Casey
Maryville, IL
who is still only a dabbler as the railroad is not running yet. On Wed, Jul 11, 2018 at 1:21 PM, Frank Sergent <fsergent@...> wrote:
-- Loren Casey
Maryville,IL -- Loren Casey Maryville, IL
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Frank, Thanks for the specific reply. I figured as much that you had to use more specialized equipment. It makes total sense to use the resin deposit printers with UV hardening. I just had no idea they were coming into the price range of specialized hobbyists yet(I ain't near there yet). On the CAD front, I had emailed the fusion 360 people(I believe it is a division of the AutoCAD people) asking about hobbyist use. They told me(a year or so ago) that hobbyist don't exactly qualify for their 'free' usage license. I didn't push it as I used to work for a s/w development company and know a bit about licensing and people who cheat the subject. I wish they were more clear on whether they are really ok with us testing out their software for free or not. I know a lot of modelers who use it, but sometimes I am too scrupulous(read stupidly conforment) I have a FabLab near me that I think has some close to professional equipment....just want to play around with my home stuff to understand some of the parameters for finer printing first. It is still a new field for the most part, and easy to get off track unless you know more than the basics. We will have Jack Burgess(of Yosemite Valley fame) here at the STL RPM meet in a couple weeks talking 3d and other 'new' technologies for rapid prototyping of things model rr'ish. Looking forward to it. LJ Casey Maryville,IL
On Wed, Jul 11, 2018 at 10:05 PM, Frank Sergent <fsergent@...> wrote:
Loren Casey
Maryville,IL --
Loren Casey Maryville, IL
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Mike Conder
This is through Autodesk? Mike Conder
On Thu, Jul 12, 2018 at 1:59 AM Michael Graff via Groups.Io <michael.graff=rocketmail.com@groups.io> wrote:
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Frank Sergent
Yes. But its not AutoCAD and not Inventor.
--------- Original Message ---------
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well, I called and talked to someone and said I was a hobbyist, and that I was not using it for profit based activities, and the person I talked to (of course not using straightforward language) told me it wasn't free for my uses. Since I used to work for a software development company, I am sensitive to illegal use of software. I have not settled on/learned a particular CAD program, and have downloaded the blender tutorial, plus when my schedule calms down, I was planning on using the CAD learning lab at the local FABLAB here. May have to revisit the 360 site. Seems a number of model railroaders have settled on Fusion360 as their go to CAD. LJ Casey Maryville,IL
On Thu, Jul 12, 2018 at 9:00 AM, Frank Sergent <fsergent@...> wrote:
-- Loren Casey
Maryville,IL --
Loren Casey Maryville, IL
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David Jobe, Sr.
First, many thanks to Frank for providing so much detail. It would appear that we are on the cusp of a great leap forward in affordable capabilities.
Loren – Where is the FABLAB located? Contact information? And, here is the language from the fusion 360 site Frank lined to earlier:
Startup: If your entitlement has been designated as “Startup, ” You may use the service if You are (a) a company, startup, or home-based business that generates less than $100,000 (or equivalent in other currency) per year from the total sale of goods or services, or (b) an individual using the service for personal non-commercial projects, hobbies, or personal learning.
It certainly appears that you or any other hobbyist should qualify based on sub-paragraph (b).
David Jobe, Sr. Saint Ann, Missouri
From: SergentEngineering@groups.io [mailto:SergentEngineering@groups.io] On Behalf Of L. J. Casey
well, I called and talked to someone and said I was a hobbyist, and that I was not using it for profit based activities, and the person I talked to (of course not using straightforward language) told me it wasn't free for my uses. Since I used to work for a software development company, I am sensitive to illegal use of software. I have not settled on/learned a particular CAD program, and have downloaded the blender tutorial, plus when my schedule calms down, I was planning on using the CAD learning lab at the local FABLAB here. May have to revisit the 360 site. Seems a number of model railroaders have settled on Fusion360 as their go to CAD.
LJ Casey Maryville,IL
On Thu, Jul 12, 2018 at 9:00 AM, Frank Sergent <fsergent@...> wrote: Yes. But its not AutoCAD and not Inventor.
Loren Casey
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David, Is in in Edwardsville, IL on the Lewis and Clark extension campus(right next to the ex NKP depot that was moved from the nearby NKP and L&M abandoned roadbeds. Here is a link to their facebook page. https://www.facebook.com/search/str/edwardsville+fablab/keywords_search# It costs $75/month for basic membership, but that includes access to everything(they have $1.5 million in equipment there), including the computer lab, 3d printers in both filament and resin, a laser cutter CNC milling machines, other large woodworking and metal working tools, a paint 'booth', plus a full time instructor/assistant on site. Only caveats are 1) deluxe users have priority over basic members on equipment - supposedly not a problem, and 2) their hours are like 2-7 PM on Tues and Thurs, and 8-2 or so on Saturday. I have gone over there and toured and talked to the main working guy(he has a supervisor) about what stuff I'd like to do and he said it should be well within their abilities. Just haven't had the money in the past, nor the time this year to start going. Figured they could fine tune my 3d printer and give me a lot of assistance with projects. Let me know if you want to go over there, and you could just swing by my place and I could drive you up there if it works, or not. LJ Casey Maryville,IL
On Thu, Jul 12, 2018 at 10:58 AM, David Jobe, Sr. <tangerine_flyer@...> wrote:
-- Loren Casey
Maryville,IL --
Loren Casey Maryville, IL
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I might be interested in continuing the business, such a great product. I am tired of being a nurse (45 years) and need a new gig to keep me interested. I would like to see how the process works as you said you would explain in a post. thanks Ken
toggle quoted messageShow quoted text
On Jul 12, 2018, at 12:48 PM, L. J. Casey <ljcasey1@...> wrote:
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