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Post by ChrisJ on Oct 1, 2019 18:48:53 GMT
Yeah, I've got that and Inventor I wish I had Inventor. Way too expensive for where I work. I like Fusion but I have problems doing 5 axis stuff. It seems limiting, but it could also just be me.
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zsuttle
5 Cubic Foot
Posts: 88
Location: Hampton Roads, Virginia
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Post by zsuttle on Oct 1, 2019 19:10:01 GMT
Yeah, I've got that and Inventor I wish I had Inventor. Way too expensive for where I work. I like Fusion but I have problems doing 5 axis stuff. It seems limiting, but it could also just be me. It's not too bad of a software, but yes, not the greatest for stuff like 5 axis surfacing
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btfarm
7 Cubic Foot
Posts: 103
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Post by btfarm on Oct 2, 2019 3:47:38 GMT
Inventor was what I used also before retiring.
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zsuttle
5 Cubic Foot
Posts: 88
Location: Hampton Roads, Virginia
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Post by zsuttle on Oct 2, 2019 21:08:42 GMT
Yeah, though at the moment, I'm having more issues with printing than I am with software. I've finished with the cap to the plug, though the pieces keep warping. I'm trying a few different designs, and settings.
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zsuttle
5 Cubic Foot
Posts: 88
Location: Hampton Roads, Virginia
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Post by zsuttle on Oct 9, 2019 4:34:35 GMT
Alright, another weekly update. I'm pretty happy with the final version of the plug that was printed on a filament 3D printer, though it lacks some of the fine details present on the resin prints. To answer Mike's question from eariler, I'm gonna try using 6-32 brass heat set threaded inserts that I bought. I might have to tweak the design of the inner plug, as on the original there's about 1/32 of an inch between the wall and the thread insert. I also took the time to machine out a prototype heating block for the injection molder, as well a nice holder/press to set the heat set inserts.
I'm still having warping issues with the resin printer, so I'll have to fix that.
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btfarm
7 Cubic Foot
Posts: 103
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Post by btfarm on Oct 9, 2019 11:55:53 GMT
Thanks for the update Zach. The work you are doing IS NOT easy and I know we all appreciate it.
Mike
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zsuttle
5 Cubic Foot
Posts: 88
Location: Hampton Roads, Virginia
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Post by zsuttle on Oct 16, 2019 23:49:17 GMT
Alright, another quick update and some progress. Fixed the issues with the resin printer and I now have a completely printed plug. I'm very happy with it so far. It's come to the point where I have to work on a mold. The original plan was to print the mold using high temperature resin, from there I would have to incorperate metal rods into the mold to make it more sturdy. This is still the viable option, but I'm not sure how well the mold would hold up before any delicate parts broke. During the winter, I was planning on converting my mill over to a CNC. This gave me an idea. Since it'll be a CNC capable machine, what would stop me from using something like electrical discharge machining to make aluminum molds? Sure it would take awhile to build the machine, but if successful, it would enable me to create professional molds for a fraction of the price. I've purchased a few books on the matter, and will be giving it an in depth look to see if it's actually plausible. There have been a bunch of machines built for less than a thousand dollars, so it could be a viable option. I'm unfamiliar with the subject, but I'm familiar with CNC and CNC conversions, so we'll see where this goes. Here's a good picture showing the difference between resin printing(Top right), filament printing (Top Left), and the original(bottom) photos.app.goo.gl/ZmKGmUsUpdmZEpoQ7
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Post by CCL2F2 on Oct 17, 2019 0:37:19 GMT
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Post by turbokinetic on Oct 17, 2019 13:04:15 GMT
Alright, another quick update and some progress. Fixed the issues with the resin printer and I now have a completely printed plug. I'm very happy with it so far. It's come to the point where I have to work on a mold. The original plan was to print the mold using high temperature resin, from there I would have to incorperate metal rods into the mold to make it more sturdy. This is still the viable option, but I'm not sure how well the mold would hold up before any delicate parts broke. During the winter, I was planning on converting my mill over to a CNC. This gave me an idea. Since it'll be a CNC capable machine, what would stop me from using something like electrical discharge machining to make aluminum molds? Sure it would take awhile to build the machine, but if successful, it would enable me to create professional molds for a fraction of the price. I've purchased a few books on the matter, and will be giving it an in depth look to see if it's actually plausible. There have been a bunch of machines built for less than a thousand dollars, so it could be a viable option. I'm unfamiliar with the subject, but I'm familiar with CNC and CNC conversions, so we'll see where this goes. Here's a good picture showing the difference between resin printing(Top right), filament printing (Top Left), and the original(bottom) photos.app.goo.gl/ZmKGmUsUpdmZEpoQ7Hi Zach. That resin printed part looks just like the original - only new!
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zsuttle
5 Cubic Foot
Posts: 88
Location: Hampton Roads, Virginia
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Post by zsuttle on Nov 26, 2019 4:45:41 GMT
Alright, thought I would post another update. I've been sidetracked by some other projects, but finally back on track. I've finished designing two molds, one for the top part of the plug, and one part for the bottom. In the meantime, I'll be resin printing a bunch of plugs as a temporary solution before I can get the molds made along with the machine. Warping issues have been inconsistent, but I've got it to a much lower failure rate, which means I can begin printing multiple at a time. The resin isn't as strong as most of the plastics, it tends to scratch and scuff easier, but it holds structurally. I've been curing them for about 30 minutes under a UV lamp, and a day or two in the window. I've yet to start cutting copper sheeting for the actual connectors, hopefully it should be straightforward. We'll see how everything goes, but hoping to have a bunch of plugs completed by early January.
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Post by elec573 on Nov 26, 2019 5:21:44 GMT
Thank you for all your efforts and expertise! I have no experience in this field but appreciate your efforts thanks !!!
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Post by ckfan on Nov 26, 2019 15:51:59 GMT
Yes, we really do appreciate your help in making these unobtanium parts available. I know it’s hard work.
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zsuttle
5 Cubic Foot
Posts: 88
Location: Hampton Roads, Virginia
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Post by zsuttle on Dec 6, 2019 0:54:07 GMT
We're in production. Over the next week I'll be doing a first run on the plugs, I've started printing the final pieces, and assuming everything goes smoothly, I should have about a dozen or so plugs completed, and ready to ship in the next two weeks. Print time is about 4.5hrs for the bottom of the plugs, and 2hrs for the top section. Each print can accommodate 2 plugs, working on fitting three on the pad. Once they're printed I'll heat fit an insert in the top. Each top will come with the two copper contacts, top and bottom halves, and flathead screw. Just want to get a count how many I need to make. Pricing will be $25 +Shipping.
Finally, if anyone else has any other plastics that thinks they should be reproduced, let me know. For now the printing will have to suffice until I can get this molding machine working, and even then I'll have to machine molds.
Again, thanks to Mike who lent me a plug to use for measurements.
~Zach
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Post by Travis on Dec 6, 2019 2:08:37 GMT
I would love the female cord end for both the tall control and the short control to be produced. I can provide examples of each.
Travis
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Post by ckfan on Dec 6, 2019 13:25:08 GMT
I agree with Travis. Those are the two other pieces that need to be made. I have a D2 that needs a short control female plug. As far as the cabinet light plugs go I’ll have to see how many I have. I know I have a few CA cabinets that need them. I have to admit that I can’t afford to buy them all at once due to having a lot of bills come up at the same time and it being Christmas time. I would be interested in one at least though. I think this is fantastic that you are doing this. Thank you so much!
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