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Discussion Starter · #1 ·
So...

I bought myself a little after-Christmas consolation gift. It's a Creality Ender 3 Pro 3D printer.

I've been cranking out some pretty handy stuff. So far the best is probably a mounting block for all of my DeWalt cordless tools. It spits out a little plastic block in the shape of the battery top, which you screw down to the surface of your choice, then just snap any DeWalt tool onto the block.

Also, survival whistles for the entire Fam... and hooks, and brackets, and ... still finding stuff.

Now I'm beginning to look for stuff to crank out for the Jeep. GMRS radio holder maybe..... Switch panels.... Flashlight holders... Maybe some placards/labels/emblems... Not sure.

Any ideas?
 

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Discussion Starter · #3 ·
The print bed is 200x200mm and it'll print 250mm tall. Roughly an 8 inch cube.
 

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Discussion Starter · #4 ·
I'm also considering printing some thin shelled models to use to make molds for casting aluminum parts. This would open up a whole new avenue for custom making things.

Custom door hinges... shift knobs, handles, hooks, mounts, winch line stops, light brackets, custom aluminum taillights...... etc... the sky is kind of the limit. Even larger items could be made by creating multiple piece items that lock together to use as the mold.

Lots to figure out....
 

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Discussion Starter · #6 ·
as long as it's short enough to fit in a 200mm square.

I'm looking at a process called photogrammetry, that let's me take a couple hundred photos of an object from all angles, and it produces a 3d model that I could print.

There's a lot I don't yet know, and a bunch of processes I need to figure out, but something like that would be cool to cast in aluminum.

The 3d prints themselves are pretty strong, but they do have limitations depending on the material used to print. The common PLA stuff I'm using so far won't fare well in a hot Jeep cabin. The PLA parts will weaken, distort and possibly de-laminate. Thus using the 3d prints to make molds and casting stuff in aluminum or zinc has a lot of potential.

There's a bunch of types of materials. https://all3dp.com/1/3d-printer-filament-types-3d-printing-3d-filament/

I see there's even a wax, which might work out better for lost-wax style casting.

I need to get a forge/furnace/crucible ,some casting sand, mold boxes and some different raw materials (brass, bronze, zinc, aluminum, ???).

However, given my day job, and miriad of other projects, I may not ever actually get around to this.... but it does sound fun.
 

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Discussion Starter · #8 ·
Round with a hole it it seems pretty easy, but how does it interface with the shaft? Splines? D-shaped?

If you want to get me some real measurements, I can give it a try. Designing the part in the software will be the tricky bit, as I've still not done that 100% myself.

The PLA might crap out on a hot day, but if I can get it printed and a workable fit, then I can spit it out in some other material, or eventually cast it in aluminum.

Now if I had the right mill, I could just carve it out of metal directly.... I'm going to need more money. >:)
 

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Discussion Starter · #9 ·
Also, I just had a thought... if it's splined, can you just clock it to get it out of the way?
 

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Discussion Starter · #10 ·
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Discussion Starter · #12 ·
A wealth of knowledge as usual.

Thanks for the brain dump @ExWrench
 

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Discussion Starter · #14 ·
That can absolutely be done, I just don't know how...yet.
 

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Discussion Starter · #16 ·
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