Sys3 'Sliding' Rail

[woodferret]

Someone posted this on Facebook....
https://makerworld.com/en/models/93682#profileId-108331

It slides! 

 

[Packard]

I am assuming that these are 3D printed.  And I know that Porsche is using 3D printing for some of its low numbers production parts, so I know that the resin can perform.

But how does 3D printed profiles compare with conventional injection molded parts for strength and rigidity? 

Separately, can they create a smooth (glossy) surface, or are all the surfaces matte finish?

Porsche is doing this in metals (pistons) and are using “additive manufacturing” instead of “3D printing”.
https://media.porsche.com/mediakit/porsche-innovationen/en/porsche-innovationen/3d-printed-pistons

The 911 GT2 RS is equipped with forged pistons as standard, but their potential for use in future high-performance engines is practically exhausted. Improvements have only been possible with changes that could no longer be realised using conventional production methods. In contrast, additive manufacturing makes it possible to implement a so-called bionic design in which material is only used in those locations where forces are transferred. For this topology optimisation, the engineers used a special design method that is matched to the specific conditions of 3D printing

 

[woodferret]

Laid flat, it doesn't matter.  Had this been printed vertically, then you'll get the layer lines that would interfere a bit with sliding.  You can post-process ABS by sanding.

I print plenty of hose port adapters in ABS and none have sheared along the layer lines.  PETG sometimes has if the walls are thin - but chonky PETG parts are very robust, more so than ABS.

If there's going to be a failure of this part, it'll be the ridge line that protrudes a bit to hold the systainer's groove.  But there's an enlarged nub on there that if given enough walls, should hold unless one purposely pulls it out cantilevered like the injected part and then wails down on it more than even a metal slide would take. 

If printed with a 0.8 nozzle, then it's really not going to go anywhere, since the interface between layers is approaching that of injection molding.

 

[simnick]

Yeah, I saw these a while ago, and want to try them out, but I need to fix a nozzle issue with my printer first. IF (big if) these work well, this would finally prove the usefulness of the sys3 groove to me.

 

[Packard]

Laid flat, it doesn't matter.  Had this been printed vertically, then you'll get the layer lines that would interfere a bit with sliding.  You can post-process ABS by sanding.

I print plenty of hose port adapters in ABS and none have sheared along the layer lines.  PETG sometimes has if the walls are thin - but chonky PETG parts are very robust, more so than ABS.

If there's going to be a failure of this part, it'll be the ridge line that protrudes a bit to hold the systainer's groove.  But there's an enlarged nub on there that if given enough walls, should hold unless one purposely pulls it out cantilevered like the injected part and then wails down on it more than even a metal slide would take. 

If printed with a 0.8 nozzle, then it's really not going to go anywhere, since the interface between layers is approaching that of injection molding.

In my mind, 3D printed parts are “resin particle board”, and I guess if the temperature of the resin is not controlled well, it could be.

Once Porsche adopted 3D printed for production parts, and not for prototypes, the process gained a lot of respect from me.  They are using the process for both metal and resin parts according to the Porsche site I linked above.

Interesting for a lot of reasons. And it allows a one-man shop with good engineering to enter the fray.

 

[PaulMarcel]

At one time, I worked for a former best friend at his company that sold replacement parts online. The interesting chatter in the industry was how 3D-printed replacement parts could revolutionize the industry. Most of this was driven by super-fans making models for, say, piston heads for an older collectible car that were no longer available. Collectors could send these files to companies who could print it in metal with the proper hardening after-printing.

The gist of the concern in the replacement parts market was that big car manufacturers could make parts for recent production models for rapid shipment, but leave older models subject to remaining inventory or on-demand 3D printing/hardening. It is actually an interesting topic given that the drive and data came from aficionados not from the actual companies (surprise, I'm sure...)

 

[Packard]

At one time, I worked for a former best friend at his company that sold replacement parts online. The interesting chatter in the industry was how 3D-printed replacement parts could revolutionize the industry. Most of this was driven by super-fans making models for, say, piston heads for an older collectible car that were no longer available. Collectors could send these files to companies who could print it in metal with the proper hardening after-printing.

The gist of the concern in the replacement parts market was that big car manufacturers could make parts for recent production models for rapid shipment, but leave older models subject to remaining inventory or on-demand 3D printing/hardening. It is actually an interesting topic given that the drive and data came from aficionados not from the actual companies (surprise, I'm sure...)

Porsche’s site (link in one of my earlier posts) states specifically that the were using “additive technology” to make out of production replacement parts.  So, in the high end market that business model apparently works.

 

[RustE]

Additive Manufacturing removes some of the constraints around conventional manufacturing processes.  Material properties are roughly cast & HIP, so as long as that is acceptable.

Another example is fuel nozzles for gas turbine engines can now have more intricate flow passages than achieved by casting and/or machining.

 

[mino]

Additive Manufacturing removes some of the constraints around conventional manufacturing processes.
...

Mainly one does not need dedicated tooling/jigs for long out of production parts, nor does one need to stock them as they can be made on-demand.

Overall, for low-volume parts, is can end up cheaper than the "traditional" way.

 

[Cheese]

Porsche is doing this in metals (pistons) and are using “additive manufacturing” instead of “3D printing”.
https://media.porsche.com/mediakit/porsche-innovationen/en/porsche-innovationen/3d-printed-pistons

Thanks for posting that Porsche link [member=74278]Packard[/member] ... [big grin]  Very interesting, not unlike how powdered metal manufacturing substantially changed the automotive parts business.

It's interesting that Mahle, which has always supplied Porsche's pistons, is only doing the 2nd op's machining and not the 3D printing.

 

[Packard]

Porsche is doing this in metals (pistons) and are using “additive manufacturing” instead of “3D printing”.
https://media.porsche.com/mediakit/porsche-innovationen/en/porsche-innovationen/3d-printed-pistons

Thanks for posting that Porsche link [member=74278]Packard[/member] ... [big grin]  Very interesting, not unlike how powdered metal manufacturing substantially changed the automotive parts business.

It's interesting that Mahle, which has always supplied Porsche's pistons, is only doing the 2nd op's machining and not the 3D printing.

Also, I’m not sure I understand what bionic engineering is.

 

[woodferret]

Also, I’m not sure I understand what bionic engineering is.

They probably meant Structural Bionic Methodology (optimization).  Most biological skeletal structures are very tuned towards the load-bearing directions taking into account the biological layering/growth that forms the skeletons.  They're taking inspiration from that - not the layman 'bionic'.  There's a whole Journal of Bionic Engineering (China) that's dedicated to drawing inspiration from biological systems. 

More traditional engineering optimization on weight focuses on a homogeneous material.  Theirs probably uses a bone remodelling algorithm.