As an entrepreneur I'm always on the lookout for fresh and innovative ideas that provide the opportunity for fun...and profit. While there are certainly others who do this on a far larger scale on this forum alone it never hurts to throw ideas out there for discussion.

First of all...for those NOT familiar with 3D printing: The basic principle of the 3D-printer is quite simple. The desired object is printed in a small tub filled with synthetic resin. The resin has a very special property: It hardens precisely where it is illuminated with intense beams of light. Layer for layer, the synthetic resin is irradiated at exactly the right spots. When one layer hardens, the next layer can be attached to it, until the object is completed. This method is called “additive manufacturing technology”. This way, complicated geometrical objects with an intricate inner structure, which could never be made using casting techniques can be produced.

Example of a 3D printer in action: http://youtu.be/u7h09dTVkdw

I seriously began contemplating the potential of 3D printers following recent threads by both SBG and Chips Motorsports regarding replacing Map Pocket Covers. Each company has an argument for why their part should be produced in the manner of their choosing...each was still a pricey option. Quite frankly, I'd rather have a piece that doesn't open at all and is just a solid arm rest covered in leather or something but that is a different discussion.

After doing a little bit of research, it would appear that the actual manufacturing of parts, depending on their complexity, could be on the VERY inexpensive side...as in a few dollars.

So...FD Community...thoughts on the viability for this type of manufacturing for creating parts that are NLA or improving on existing OEM parts? As with any technology this will only continue to improve and become a more inexpensive option in my IMHO. Anyone with actual experience with 3D Printing? Discuss.

 

I am familiar with 3D printing. Do you have a printer of your own?

 

Back in 2004 my High school got funding in the drafting department, we got new computers and a 3D printer, It was very impressive for rapid prototyping. I drew up a set of BBS Lms and printed it, within 3 hours I had a rim with a diameter of 4 inches. awesome machine!

 

As with all rapid prototyping methods, you should carefully consider if the accuracy of form, level of detail, color, and strength/durability are adequate.

I haven't had my hands on the latest/greatest 3D printing (RP) output, but these are the areas where RP is traditionally far behind a normally produced part.

David

 

^exactly, the wheel I made was great for show, but its basically layers of plastic with air pockets between the layers, so its not very strong. I would imagine that you could make a mold from the prototype and use that mold and fill it with a liquid plastic compound that will harden and make a more solid piece.

 

these printers are a blast to play with, sadly my school district got one the year after i graduated but i knew the teacher well enough to let me come in and make some stuff..

 

I have never used one, but I think a buddy of mine (engineer) in Boston who has.

Here are my thoughts on how I would use the 3D printing capabilities.

How about starting by printing the passenger door handle that might be stronger than the OEM and cheaper than Sakebomb's?

Then depending on the material that the end products comes out in why not create a rear diffuser that has more flex (like the OEM front lip) but that same efficiency as the aftermarket (rock hard pfc) products.

Then I would spend some quality time assessing what other parts tend to fail over time or are actively being searched by members. I would bake these items into the production costs and see if there is any sense in producing them.

Keep in mind I wouldn't limit this only to RX-7's; I see the potential to take over a number of manufacturers. ...think OEM parts without the OEM price.

I don't know.. just a thought. Let me know if any of you want me to try out any products that they have created.

 

Leno did a segment on them. I can't wait till the printers are freely availible so I can make more printers.

 

From what I understand, the latest printers create a product that is hard enough to use for industrial purposes. My research at this point is very tentative and I could be absolutely incorrect. I am reaching out to a couple of companies about this however.

 

from my understanding the newer printers do allow for some abuse to the made print. the resin and the material they use now is much stronger and can perform a function that the real thing would do, but of course on a smaller scale.

 

im only familiar with an abs 3d printer... how good are your cad skills?

 

That quite possible, remember it was 2004 then so im sure things have changed

I dont know how large these printers can get but I'd assume to make a piece as big as a diffuser would be extremely costly and not worth it as opposed to making a mold and doing fg or cf.

 

Oh I'm not thinking about anything as large as a diffuser...at least not yet. More along the lines of those annoying items like Map Pocket lids. Hell, I'm not saying I'll even do this but perhaps the discussion will inspire others to do so. I believe competition in the marketplace generally brings the best out for everyone but I'm a blatant capitalist at heart. =)

 

Ya my money would be on making a mold from foam, then making a silicone mold from that, then injecting a liquid plastic that will harden.

http://www.youtube.com/watch?v=Fxk7z...eature=related

 

Wow things sure have gotten high tech. Yeah I see opportunity in this for sure. How about making me a set of aluminum rotors?

 

I am in school for engineering and we have one on campus. It is great for seeing your design in a hands on form, but the parts come out fragile, even when printed solid. Another problem with the machine is when it comes to very fine details it just can't hold the tolerences required.

One great drawback to the process of 3D printing on this machine is the amount of time it takes for a full size part to be produced, ussually near or over 10 hours.

I am only going on my experiences with our 3D printer which is about 2 years old. I'm sure things have advanced greatly since then.

 

Thank you for everyone's input. I'm in the learning process and I figured there would be members a LOT smarter than I am with actual experience. I appreciate everyone chiming in and look forward to following input.

 

There are 3d printers that create solid metal with useful material strength. But my impression (haven't priced one) is that you pay for that strength and accuracy. Plus the time to produce is slower.

David

 

^ ^ ^ a CnC machine.

http://www.youtube.com/watch?v=QsmiIeAkE-o

I have seen FD aftermarket pulley knockoffs (made by CnC machines)for sale on Ebay. I am sure there's tons more stuff.

 

Arise thread!

On the subject of 3D printing interior parts I've been doing some contract work with a 3D printing and prototyping company and one of my friends now works there. He was stating that 3D scanners aren't like on TV and you still need a skilled CAD artist even after the scanning, especially something like an air vent. It would almost be cheaper to break out the dial calipers and draw a part that way and then have it printed, you could draw it yourself or contract them to do it instead of scanning.

For high strength he recommended FDM printing, but as I was talking to him he realized it would make more sense to make a 3D print mold (possibly using SLA or FRSLA for detail and texture) and have them tooled up for production. Or plastic casting. I'm not sure what the difference is between injection molding and casting. This isn't a one off kind of deal as it is more for a production run.

As our parts become more scarce it may make sense to make a run of interior parts and stock them for sale. If anyone here sees this as a business opportunity you should hit them up. The one you would need to talk to is my friend James and his email is james@dinsmoreinc.com to see their stuff you should check out their website.

I did some of the product photos for them, anything with a white background should be mine.

 

I have a 3D Printer, the plastic (PLA) definitely won't break or anything in terms of strength and durability. In fact, you can choose how solid or hollow a piece is (shells/infill). PLA is not cheap, but it's definitely way cheaper than what a map pocket would cost you at Mazda. As an estimate, the map pocket would probably run $3-4 of plastic to produce and probably a couple hours of printing.


Makerbot Replicator 2


Squirrel!

 

I am a CAD draftsman at the moment, in the mechanical engineering department at our state government-owned electricity company here in Australia. Sadly, I havent had a chance to play with a 3D printer yet, as the technology in Australia is too expensive and not widely available yet.

I am however, very fluent with AutoCad 3D and Microstation, having learned when I was 16, and been drafting in a professional role for a little over 10 years now, with a fitter/machinist qualification also.
I see a lot of growth for the 3D printing market. Imagine, instead of downloading a movie to watch, you download FD door handles or headlight covers... Dash parts... I mean look at the FD. Half the car is made out of plastic. All one would need to do is strip a wreck to parts, use a 3D scanner to quickly make 3D AutoCad models, then tweak as needed, and print. The customization of each part would be limitless.

 

I think it gets fairly expensive if the parts are large (like a front lip), because most of the cost-accessible machines only do a relatively small part. Unless you have access to one of the pro machines that do big parts for free, it would get pretty expensive.

There's a lot of potential for stuff like brake ducts, etc., if you had CAD expertise and access to a printer.

 

3d printing is just for rapid prototyping but it takes a long time for the parts to be printed. I made a little train and a 1x2 inch model took a couple hours to make. Anything bigger and you will be there all day.