Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially...

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Mass-Producing Freight Cars at Home Robert Bowdidge

Transcript of Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially...

Page 1: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Mass-Producing Freight Cars at Home

Robert Bowdidge

Page 2: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 3: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 4: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 5: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 6: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 7: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

1 - 3 cars

5 - 10 cars

10 - 30 cars

30 - 100 cars

Make one freight car.

Make a few freight cars for me.

Make freight cars for friends.

Sell freight cars.

Levels of Effort

Page 8: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

What’s Possible on a Hobby Printer?

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SP W-50-3 Gondola “Hart Convertible”

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SP W-50-3 Gondola “Hart Convertible”

Page 11: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 12: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

SP W-50-3 Gondola “Hart Convertible”

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SP W-50-3 Gondola “Hart Convertible”

Page 14: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

SP CS-35A Flat Car

Page 15: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

SP CS-35A Flat Car

Page 16: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

SP CS-35A Flat Car

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SP “Battleship” Gondola

Page 18: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

SP “Battleship” Gondola

Page 19: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 20: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
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1 - 3 cars

5 - 10 cars

10 - 30 cars

30 - 100 cars

Make one freight car.

Make a few freight cars for me.

Make freight cars for friends.

Sell freight cars.

Levels of Effort

Page 22: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

1 - 3 cars

5 - 10 cars

10 - 30 cars

30 - 100 cars

Make one freight car.

Make a few freight cars for me.

Make freight cars for friends.

Sell freight cars.

Levels of Effort

Page 23: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

How 3d Printing Works• Several different kinds of printers - some only for

industrial / commercial use, some hobby use.

• key points: all these printers have appeared because the patents expired, expect more of all of these

• Each printer type has its own strengths and weaknesses

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FDM - squirt plastic

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Shapeways: layer by layer

Wax Final Part Wax

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Liquid resin + light

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Liquid resin + light

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Liquid resin + light

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Liquid resin + light

Page 30: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Liquid resin + light

Page 31: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Liquid resin + light

Page 32: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Liquid resin + light

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Liquid resin + light

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sending to printer

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Remove Supports

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Body done

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And We’re Done!

Page 40: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

How we make one car• Figure out what to build

• Create a 3d drawing describing the object.

• correct thicknesses, holes, etc.

• Prepare for printing: facing, etc.

• Send to printer

• Clean up, finish.

Page 41: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Creating 3D Model• I use SketchUp - free non-commercially (get plugin for STL)

• Works on idea of extruding shapes

• Plan to think at least a bit about what you’re doing - can be hard to move sides out 2” if too narrow

• easy to use, but poor for intersecting round shapes (don’t do locomotive cylinders)

• Work in actual size (and do lots of math), or do in scale size, then scale down.

• HO scale inches to actual mm = 0.292, O scale inches to actual mm=0.529

Page 42: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 43: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
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Page 52: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 53: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 54: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 55: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 56: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 57: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 58: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 59: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 60: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at
Page 61: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

SP CS-35 36’ Flat Car

(SketchUp file at thingiverse.com/bowdidge/designs)

http://thingiverse.com
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SP CS-35A 40’ Flat Car

Page 63: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

What’s Easy in 3d Printing

• Choose models that you can’t get otherwise

• Can’t be made from molds

• Repeated, tedious details

• Complex, difficult to assemble

Page 64: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Make In One Piece

Page 65: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Find Repeated Parts

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Use Floating Details

Page 67: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

• add drawing here

Add All the Detail

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Detail on all sides

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Throw On More Details

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Emboss for Texture

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Undercut details

Page 76: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Make Multiple Variants

Page 77: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

What’s Hard in 3D Printing

• Surface still a bit rough - better for wood than metal

• Plain flat surfaces easier to add with styrene sheet

• Warping an issue with thinner pieces

• Requires effort of resin kit to finish

• Size limits on printers, cost of Shapeways

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Good Cars To Make

Page 79: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Garth Groff photo, wplives.org

Good Cars To Make

http://wplives.org
Page 80: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Measurement Form One(HO scale)

Formlabs(inches)

Shapeways FUD (inches)

Minimum wall thickness 2” 0.015” 0.02”

Minimum unsupported wall 2” 0.023” 0.023”

Minimum thickness for handling 4”

Minimum unsupported overhang .0.040

Maximum span 0.087” 0.082”

Minimum wire width 1” 0.012” 0.023”

Minimum unupported wire 0.060” 0.060”

Minimum embossed detail .75” 0.003” 0.006”

Minimum engraved detail .50” 0.013” 0.015”

Minimum hole diameter 6” (clean), 2” (pilot hole)

0.023” 0.019”

Design Guidelines

Page 81: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

1 - 3 cars

5 - 10 cars

10 - 30 cars

30 - 100 cars

Make one freight car.

Make a few freight cars for me.

Make freight cars for friends.

Sell freight cars.

Levels of Effort

Page 82: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

1 - 3 cars

5 - 10 cars

10 - 30 cars

30 - 100 cars

Make one freight car.

Make a few freight cars for me.

Make freight cars for friends.

Sell freight cars.

Levels of Effort

Page 83: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Tweaking the design• Speed: print more than one, change orientation

• Yield: fix details and support structures to get more good models.

• Cost: adjust design to cut material, support structure

• Usability: weight, coupler height, truck height, turning radius

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Speed

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Yield

• Why are details like vertical posts printing badly?

• What areas are hard to trim?

• How do I cure the models? How do I fight warping?

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Minimize support structure

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Don’t Print Big Flat Areas

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Weight

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Weight

Page 93: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

1 - 3 cars

5 - 10 cars

10 - 30 cars

30 - 100 cars

Make one freight car.

Make a few freight cars for me.

Make freight cars for friends.

Sell freight cars.

Levels of Effort

Page 94: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

1 - 3 cars

5 - 10 cars

10 - 30 cars

30 - 100 cars

Make one freight car.

Make a few freight cars for me.

Make freight cars for friends.

Sell freight cars.

Levels of Effort

Page 95: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

In real manufacturing, making fifty is a test run.

For me, that’s next year’s sales.

Page 96: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Mass-Producing• Quick decisions

• Comparing several prints

• Go / No-Go Gauges

• Records, checklists, photos

• Fixing almost good enough models

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It’s trivial to change a design. When to stop?

• Changes in model affect instructions

• Changes in model, support structure, orientation affect reliability

• Do you still sell older versions?

• Do you know which are the older versions?

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What’s the Difference?

Page 102: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

What’s the Difference?

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1 - 3 cars

5 - 10 cars

10 - 30 cars

30 - 100 cars

Make one freight car.

Make a few freight cars for me.

Make freight cars for friends.

Sell freight cars.

Levels of Effort

Page 104: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

1 - 3 cars

5 - 10 cars

10 - 30 cars

30 - 100 cars

Make one freight car.

Make a few freight cars for me.

Make freight cars for friends.

Sell freight cars.

Levels of Effort

Page 105: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Let’s Talk About Money

• What’s a reasonable price?

• What’s the cost per car?

• What are the other costs?

• What’s the real yield?

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Price?

• CN narrow gauge gondola on Shapeways: $170

• Shapeways (40’ car, no markup): $60-$70

• Resin kit: $35-40

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PricesSale Price $35

Cost of resin 25 ml, 15¢/ml $3.75

Depreciation of machine assume 1000 cars $3.00

Details Retail $4.50

Decals 75¢

Labor (manufacturing) 15 min @ $30/hr $7.50

Labor (packing) 10 min @ $30/hr $6.00

Packaging 65¢

Total $26.15

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Material Cost

• Typical car: 18 cm3 / 25 cm3 with support

• Formlabs resin: $3.75 (15¢ / cc)

• Shapeways: $68 ($5.00 + 3.49 / cc)

• Includes labor, material, website, shipping.

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Parts• Additional parts - wire for grab irons, screws, detail

parts, decals - big risk for small manufacturers

• Buy wholesale: minimum number,

• Buy retail: high prices

• If I run out, production stops

• For small runs and testing a concept, this is a big risk

Page 110: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

What to Do About Parts?

• Wire, grab irons, brake wheel, steps: Don’t furnish.

• Decals: Harder to find. Custom-print these.

• Screws, etc. Buy them. (Sometimes local!)

• Detail parts? If only I had a magic factory…

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Page 112: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Making Detail Parts

Page 113: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Assumption: material was major cost. Reality: Labor dominated

• Tending printer

• Rinsing models

• Trimming off supports

• Drilling, tapping, cleaning up, inspecting

• Distinguishing good from bad

• Part of Shapeways cost is all of this.

Page 114: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Assumption: Print on Demand

• Challenges

• identifying good cars, cleanup

• getting together parts

• getting into rhythm for wrapping, packaging

Page 115: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Assumption: Cost Per Model Dominated

• Reality: One-off Costs dominated

• building and photographing pilot models

• finding boxes and packaging

• figuring out how to wrap

• instructions

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The Box

Page 117: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

And If the

Printer Fails…

Page 118: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

How Did It Go?• Sold around 60 cars, mostly “as-built” version.

• Announcements: friendly blog, mailing lists, word of mouth

• Most sales from friendly blog, dealer queries.

• Plan: regularly release new cars

• Reality: printer problems, new day job

Page 119: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

So should you do this?

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Fun Only?• Want to make a fleet for friends and kindred spirits?

• Choose cars that folks can’t get any other way.

• Find ways to get friends to help with labor

• If too much work, then go to Shapeways.

Do it.

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Commercially?• Possible, but not a route to easy money

• Labor and yield are the two biggest challenges

• Print a bunch in bulk and sell as you can

• Regularly release designs to amortize startup costs

• Tweak design, process to minimize your effort

• Fall back to Shapeways when it gets annoying.

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More Info?• Jack Burgess’s 3d printing talk: Saturday, 10:30 a.m.

• Sample SketchUp design: CS-35 flat car @ thingiverse.com

• See these slides at vasonabranch.com/3dprinting

• Follow progress at vasonabranch.blogspot.com

• Send questions to [email protected]

http://thingiverse.com
http://vasonabranch.com
http://vasonabranch.blogspot.com
mailto:[email protected]
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Best Use for 3D Printing?

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Structure Detail

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Clutter

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Odd Structural Parts

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Figures

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Vehicles

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Set Dressing

Page 130: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

More Figures

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Freight Car Ideas?

Page 132: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

Other Scales

• Basics of model depend on scale

• robust enough for handling, not too chunky

• some details don’t match printer’s capabilities

• bolsters, coupler pads, clearances need to be changed

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Page 134: Mass-Producing Freight Cars at Home · Creating 3D Model • I use SketchUp - free non-commercially (get plugin for STL) • Works on idea of extruding shapes • Plan to think at

SketchUp: Advanced techniques - modelling - Portfolio · 6 IT Learning Prograe SketchUp TIMZC Using Google Sketch up for the first time Task Set up SketchUp Steps Launch SketchUp

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sketchup ,google

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SKETCHUP CECILLE

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Modul - Sketchup

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MMM Technology in Ultrasonic Extruding, Tubes and …mastersonics.com/.../drawing-machining-extrusion.pdf · MMM Technology in Ultrasonic Extruding, Tubes and Wires Drawing, Metal

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Tutorial de Sketchup - TALLER TECNOtallertecno.com/sketchup/Tutorial-Sketchup-8.pdf · Ministerio de Educación Tutorial de Sketchup Crear, compartir y presentar modelos 3D Plan Integral

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