3D Printing Boxster Parts

[BoxNasty]

Hey,
So, there's a manufacturing revolution going on right now. Hope you heard about it. If not: please read this. In a nutshell: physical objects can be made by fusing powders/extrusions of raw material in successive layers. No hard tooling is ever needed, so customized parts can be made relatively cheaply. Like this:



I decided to create my own shifter knob for my 1999 Boxster. I created the 3D model of the cap with Sketchup . Using Shapeways, a 3D printing manufacturer, I uploaded my model and then ordered a physical copy of it, made in stainless steel. HALIX (tm) is the business name of my shop, just so you know.

The part hasn't arrived yet, but I'm anxious to get the word out that 3D printing is going to be commonplace soon for replacement parts. Real nylon 12, stainless steel, silver, ceramics, glass, sandstone, rubber, and more are all available from Shapeways. I'm not affiliated with them, BTW; I'm just a designer. Other companies can print in aluminum, carbon-fiber reinforced nylon (I've tested it, and it's amazing), Inconel, PAEK/PEEK, edible stuff like meat and frosting, and more.

Anyway, if you know how to 3D model and want to design your own cap using my template, download the Sketchup file here or the .stl file here. If you want to learn how to 3D model, there are tons of resources on the web. I personally made this how-to guide for absolute beginners.

Additionally, if you like the design I've showcased above, you can purchase it here. If you use my template for your own design or liked my 3D printing start-up guide, feel free to donate a buck or two to nealbrace@gmail.com using Paypal.

So, what else are we going to make?

[nieuwhzn]

Please note that the accuracy (= minimum detail) of the Shapeways stuff is not that great. It looks that their major market is gadgets and jewelry, _not_ precise engineered pieces. As always you will get what you pay for. There are other companies that _are_ doing accurate rapid prototyping. Our engineers have been designing some pretty nice pieces which were then outsourced. I you want I can ask which company was used.

[BoxNasty]

I definitely agree with the accuracy part, but metal at Shapeways (and Ponoko and iMaterialise) is about 1/5-1/7 the cost compared to others. My parts have come out fine, so far. It's just a matter of time before prices fall even more and accuracy improves, which I'm looking forward to.

[nefarious986]

Jay Leno have these machines in his garage. He uses it to produce parts for his antique cars that no one have parts for anymore.

Scan the broken part into the 3D scanner .. modify / re-engineer / strengthen where needed .. print out new out.

Its amazing technology. Can't wait until this is affordable enough ( and easy enough to us ) so that its available to the masses. Not everyone have the time to learn CAD. LOL

[thstone]

What was the cost of having the shift knob made in stainless steel?

[BoxNasty]

It's just around $30 for the "template" version and maybe $28-29 for a version with a design carved into it.

[thstone]

Originally Posted by BoxNasty

It's just around $30 for the "template" version and maybe $28-29 for a version with a design carved into it.

Wow. That's actually fairly affordable. There has been amazing progress in this type of technology.

Can you post a pic of the stainless steel knob when you get it? Would like to see the end result. Thanks.

[IMACMAN]

Hi Just joined forum. About 3 years ago, I came across the 3D print technology, and did some research... long story short, I just finished building a CNC router, that will cut plastic, wood, aluminum and most softer metals... the 3D Printing is an additive process and the CNC milling is a subtractive process. My CNC can be fit with an extruder that will make it become a 3D printer. During the build process I bought a Milling machine and a Metal lathe... I've been teaching myself to use both, and it enabled me to finish my CNC build.... In the 'Real World" I'm a Graphic Designer / Artist, so these abilities helped alot with the 3D design CAD aspect of the process. I haven't done much with it yet, but I should be able to develop pretty much any part I should need ( taking in trial and error of course ) I'm keeping an eye on the 3D print technology... and the prices are coming down as the quality increases. It's very exciting stuff for all DIY'ers... they day is fast approaching, when you will need a part... and simply sownload the File ( or even the G-Code ) and 'Print" the part in your own shop.... Imagine the market for "Custom" work!!! it's a manufacturing revolution that's gonna be huge!... and coming fast.


Cheers IMACMAN, Newfoundland