Custom fabrication is becoming easier and easier
Posted 01.18.2012 at 11:02 am
6 Comments
Bracketology
Vin Marshall
Recently I converted my old Ford pickup to diesel, and I needed to make a bracket to hold a throttle position sensor, which helps to control the new transmission. Often I wing this sort of thing, working from notebook drawings or cardboard models. But this time I decided to use 3-D CAD modeling, CNC manufacturing and 3-D printing to design and fabricate the part to the exact specifications I wanted.
Printed Bracket: Step 1: Vin Marshall
STEP 1: DESIGN
Using Alibre Design Expert 3-D CAD software, I created an assembly, which lets you model previously designed parts as they will eventually fit together. In the assembly, I placed my throttle position sensor (TPS) over the fuel-injection pump to derive all the dimensions of my bracket from those two parts. I then modeled the bracket that will attach the TPS to the pump.
Printed Bracket: Step 2: Vin Marshall
STEP 2: FABRICATION
I first 3-D-printed an inexpensive prototype to verify that my design would work. Then I looked to machine it. Parts better suited to conventional machining require a multi-axis CNC machine. For anything made from flat parts, a laser cutter is the best tool. Because my bracket would be made of sheet metal, I took the CAD model to a local shop that has a punch press, another type of CNC machine.
And, of course, video of the construction:
FABRICATION SHOPS AROUND THE WEB
eMachineShop: For laser cutting, injection molding, and a variety of other machining processes.
Ponoko: For laser cutting of plastics, cardboard, wood and other materials.
Shapeways: For 3-D printing.
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Those 3D programs are expensive. But if you can get a hold of one, they can be put to good use.
Ah, I certainly like a clean machine!
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I feel like this article is seriously lacking. There could have been much more detail.
you should check out reprap, it's a more ugly but all around cheaper 3-d printer. it's parts are open source and it is 50% self manufacturable you just need to buy the axles and motors.
I'm personally taking the easy route when i go back to college in the fall; auto-cad offers free program licenses to students who can prove they are going to college (simple deal really). i don't think they really care what classes you are taking but let's be honest, if your salivating over professional drafting tools like auto-cad your going to be in some form of engineering. i know i can't wait.
my first thing I'm going to try is a rib structure for a suit I'm thinking about.
to mars or bust!
To those looking for good CAD packages (especially with 3D solid modeling capacity,) look at both FreeCAD and OpenSCAD (respectively, http://sourceforge.net/apps/mediawiki/free-cad/index.php?title=Main_Page and http://www.openscad.org/ )
There are a number of people successfully using these packages to generate .STL files compatible with the software controlling RepRap, MakerBot, and other 3D printers. There are similar workflows which will yield files suitable for sending to eMachineShop, Ponoko, etc.
To Mr. Marshall: why would you take an engine as beautiful as the Cummins you have there and put it in... a Ford?! That beauty belongs in the beat-up old Dodge it came in :-) (like this one: http://tripplilley.com/u/tlilley/babe.jpg )