3D Printing on FEs?

[Qikbbstang]

Years ago I scored a fully functional adjustable wrench completely 3D printed at PRI - it was not metal but certainly created thoughts as to how 3D could be utilized. Included is a link to a 3D jet engine that I could find nothing that it has been "run" on search. Using alloys in a 3D printer that could work in the hostile environment of a jet engine is off the charts. Just wondering if anyone has utilized 3D for FE components such as intakes, heads, rockers etc yet?

https://www.youtube.com/watch?v=dRQB1SY4d6U

[ScotiaFE]

An even better jet engine.

 https://www.youtube.com/watch?v=fmpmneSSClM

[jayb]

I'm planning a 3D printer purchase to do test intakes from ABS plastic.  I think they will survive for a while, at least on the dyno or a race car.  There are some challenges associated with doing the printing of large, hollow areas, but I think I can work through it.  Hopefully I'll have something this fall...

[turbohunter]

I'm planning a 3D printer purchase to do test intakes from ABS plastic.  I think they will survive for a while, at least on the dyno or a race car.  There are some challenges associated with doing the printing of large, hollow areas, but I think I can work through it.  Hopefully I'll have something this fall...

 

[cammerfe]

Add a dozen or so of those smileys from me!

KS

[ScotiaFE]

It won't be long and you will be able to print your own fembot.
Now you would think that is great thing, but what happens when
they start demanding rights and making you do the dishes.
And for us prev's, well that would be just wrong

http://news.bbc.co.uk/2/hi/science/nature/7946780.stm

[BruceS]

Jay, 3D printing of intakes with ABS shouldn't be too much of a stretch; aren't many modern intakes made from composite material?  Not sure how close to ABS is to the material the automakers use. I guess what I'm saying is, a 3D printed prototype intake might last longer than we think.

Looking forward to the results!
Bruce

[Dumpling]

Biggest problem currently might be the size of the items that can be 'printed'.  An intake wold probably be too big, unless done in pieces (or individual runners...).

[jayb]

I've got my eye on a machine that will do a 600mm cube, which should be plenty big.  I think the biggest issue is warpage of the large pieces that you want to print.  If I could get away with printing PLA, I don't think it would be a big problem, but PLA melts at too low of a temperature for any engine application.  ABS is good to 270F or so, which ought to be OK for an intake, but it tends to warp.  I bought a spool of the ABS plastic used in the printers and soaked it in race gas and pump gas for several days, and it held up, so I think it will be OK with fuel.  I'm currently experimenting with a smaller 3D printer to get the hang of it, before I spring for the big one...

[mmason]

Here is a 3d printed car.

http://dprintedcar.webflow.io

[cjshaker]

3D printing is the wave of the future, even though it's happening now. I've been watching it for years. Using powdered metal is also an option, and something that is being used currently.

[Qikbbstang]

Can't help but chuckle on thoughts of these guys claiming to make a jet engine on 3D and having interest from jet engine manufacturers. I just think about the extremes jet turbine engine's see: even in what is considered a small jet turbine 25,000+ rpm, massive heat and cold variations from combustion engulfing the blades, centrifugal forces and loads.  If they have not tested the engine logic say's they're just the first guys to publically show a jet turbine made on a printer. However making one on 3D to actually work -------aghhhhhhhhhhhhhh!

[machoneman]

I've got my eye on a machine that will do a 600mm cube, which should be plenty big.  I think the biggest issue is warpage of the large pieces that you want to print.  If I could get away with printing PLA, I don't think it would be a big problem, but PLA melts at too low of a temperature for any engine application.  ABS is good to 270F or so, which ought to be OK for an intake, but it tends to warp.  I bought a spool of the ABS plastic used in the printers and soaked it in race gas and pump gas for several days, and it held up, so I think it will be OK with fuel.  I'm currently experimenting with a smaller 3D printer to get the hang of it, before I spring for the big one...

I wonder what the material is some race manifolds (or Ford OHC engines) are made of? Any OEM material would of course  have been put through a battery of tests to ensure longevity , fuel proofing, etc. I still think for many engine parts 3-D printing is more beneficial for rapid computer-to-part proof of concept work even if the part may not last forever. In Jay's case, he could make a special manifold, test it and then make rapid fine tuning changes, albeit may require a 2nd 3-D print job. Then, the finalized intake could be cast in aluminum or re-made of a more durable plastic. JMO! 

[jayb]

Bob, that is exactly how I'm thinking about this.  Design a manifold for the intake adapter, dyno test, tweak the design, dyno test again, etc.  This would be a fast and relatively inexpensive way of developing an intake that you know is going to work, before spending thousands of dollars on tooling to get it cast in aluminum.

[babybolt]

I saw a sterolithographic intake manifold at least 15 years ago that had been created, dyno tested and tweeked. 

A friend worked at a company who had the really big dollar machines to create metal 3D parts.  This was about 5 years ago.  A small 2 or 3 inch part was $1000 to $1500.