3D Printed Car Parts? We put ASA to the test!

never run in the uncomfortable situation when you're working on something the very thing you don't want to happen but is likely to happen happens [Music] hello it's as a Romania design here now my particular situation I work on vehicles a lot and it's inevitable to run across something breaking in the process of replacing parts or vehicle restoration the automotive industry uses a wide range of plastic and metal parts and they're put under the extreme conditions be it high heat or frigid cold not to mention the hundreds of thousands of heat cycles they have to go through their entire lifespan we also have to remember here that like most industries in the world the parts construction and its material makeup is greatly influenced by its cost so the part I have here is a brake line clip that holds their two rear brake lines to the body of my Audi a8 on these particular vehicles with 4-wheel ABS and traction control they actually run the two rear brake lines from the front engine bay area along the frame rail to each rear wheel on this particular vehicle the lines run around three meters or so and there's quite a lot of these clips supporting them along the way I have to say that these are some of the nicest clips I've come across they're over engineered just like the entire car and I really have an obsession with being overkill and these really put my mind at ease these remain the 90s by TRW which is actually now owned by ZF and they've served my car well for almost 20 years they actually have a very unique design and that there's technically three parts here unlike the more common one or two part brake Clips and I say three because we have a center core here which is hollow with this kind of rough pattern in here that helps it screw on to the studs on the vehicle then there's this rubber over moulded onto that which helps isolate it from the actual mounting point on the frame of the vehicle it's definitely overkill as you likely wouldn't see much longevity gained from this but it's still super cool how much time they put into every single little detail this part and the vehicle as a whole I'm actually glad that they went with plastic on this part because it's one less thing I have to worry about corroding and though it's lasted this long Plastics that have been through countless heat cycles UV exposure and have likely absorbed some moisture they actually lose their structural integrity and these clips have become so brittle that they separated at the weakest location when I was trying to remove the brake lines and I was being gentle mind you now I could just get some generic great clips to replace these to solve the issue but as I said I can't help but be overkill here not to mention I would like to as much as possible keep this car entirely stock with no mismatching parts or jerry-rigging so first I did some research and had an extremely hard time finding these clips from someone in the US I found some overseas but they didn't have the quantity as I needed not to mention the prices were ridiculous with what they had so this really sounds as if I backed myself into a corner and found a problem that must be solved with either a wallet or something that can take these plastic spools and turn them into something usable like this hmm [Music] so first I use fusion 360 to redesign these clips in a way that they were remotely 3d printable I made three parts with the center stud and frame being the rigid a si or a BS and the support core being a flexible TPC or TPU I also had to account for the stud sliding into the core unlike the original design which was over molded next was exporting my models to STL's in high detail slicing and slicer and then sending these to the printers to make some very rough prototypes I want to note for this entire project I'm using 3d X tech filaments they're extremely high quality filaments made in the USA best part is they're actually local to me and they make some of the best film it's on the market their biggest specialty is engineering grade materials such as ultim Pei 90 85 or Tenten then there's also PPS F PSU PC flex AAS a nylon hips and then they have the usual ptg abs and PLA they also have carbon fiber versions of pretty much every filmin that they make and they've been releasing some really great-looking ptg colors lately this video isn't sponsored by 3d X tech but I really liked their filaments and I've included a link to their website in the description below so I had to change the Talon TSA's between the three parts ever so slightly and after some cleanup they weren't too bad at all I'm functioning correctly however me being picky I was frustrated with the detail as I wanted the parts to look good function correctly and print in a way that I had to do little to no post-processing this is the perfect situation for me to use multi material and show you how you can make a complex part out of the excellent a si support the overhanging geometry with the hips material which you then dissolve initially I had some issues with the multi material stripping out film on the changes I then realized I had a two millimeter inner diameter Bowden tube in the hot end rather than the required one point eight to one point nine inch tube if you're curious about this check out the link below point to some info on this after replacing a tube I got some prints help and then I had some serious issues with layer bonding the struck me as odd though because literally a foot from the MMU mark to s I had both of my mark threes printing si and abs with literally zero issues and I had made sure I was using the same print settings as well that's led me to believe that maybe I was not wiping enough and my materials were mixing leaving me with a eighty to ninety percent as a material and maybe ten to twenty percent hips not to mention they don't bond well together at all to attempt to solve this I changed the wiped our dimensions from the original sixty by twenty millimeter to a sixty by thirty when priming the nozzle between filament changes I could easily see the transition from the black si to the whitish colored hips and saw a nice improvement as the color was there ninety percent plots however with this I still ran into layer bonding issues so I upped it to 60 by thirty five watching the film it changes again I could not see any visible color mix at the end of each wipe so I figured I was all set however on this print I yet again ran into another Jam and had to cancel it I was glad I did because when I went to test layer bonding again I had the exact same issues it appeared better but still unacceptable because in either part to be a hundred percent bonded for the conditions they're going through at this point I had had it with my a si and hips attempts this has nothing to do with the materials or the manufacturer as I tried changing that to my theory is due to the particles being mixed in a single nozzle and is nearly impossible to ensure a completely clear nozzle between filament changes this is okay in most cases since most materials we 3d print with bond well to each other however a si and ABS do not bond well to hips at all even with no interface layer that breakaway with ease the MMU is a great setup for printing with multicolor but I cannot get it to work with multi material so with these findings and taking a break from the MMU I moved on to my next alternative I made the part extremely printer-friendly bikes sending the faces to the edge of the centered cylinders geometry which gave me a flat top and bottom this helps with warping and also makes the part super strong this is also perfect as it's the orientation I want to print in as the flex direction is perpendicular to the layers printing a few test Parts I got to a point I was happy with I had minimal drooping in the center circle and had an extremely strong part I printed a batch of each part and began final prep so here we are start to finish this wasn't a bad project though the MMU dilemma was a bit discouraging but we pushed forward and found a reasonable solution overall I'm pretty pleased with how this turned out I got to save some money redesign some parts and make them and get one step closer to having my cars restoration project complete for those of you with the perusal MMU kits I'd like to get the discussion going on how we can fix this issue I ran into maybe I did something wrong here or maybe there's some constraints to this particular extruders design you can look forward to more videos on this channel as soon as we get things ramped up in the meantime I hope you enjoyed this episode see you next time on any design so there's the new one and there's one of the old ones I just left this one on there as well just for reference but I'm gonna replace them all with these since they are much stronger so there we go yep

Channel: E&E Design

Views: 124,619

Rating: 4.7359476 out of 5

Keywords: 3d, print, printer, printed, abs, asa, tpu, tpe, tpc, flexible, filament, spool, spools, orignal, genuine, prusa, mk2, mk2s, mk3, mmu, multi, material, multi-material, auto, automotive, car, part, parts, audi, a8, functional, design, cad, fusion, 360, slic3r

Id: kPxun8d4R9Q

Length: 8min 45sec (525 seconds)

Published: Thu Feb 15 2018