Custom 181 bracket, CAD to 3D Printed in ABS plastic.

[Solomon Grundy]

After my one day training stint I have been looking for excuses to get my hands dirty with our departments industrial grade $60,000 3D Printer and learn more of its capabilities. This is old hat to me as our last 3D Printer died in 2007. Being I train folks in various CAD software packages I decided to use Pro/Engineer now called Creo Parametric to design a simple but fun bracket for the area between my role cage and the door center column. Below are several pictures of that fun process. The only real issue is that I badly assumed that I could make two and just flip it to the other side. Being my beast has been through the mill, off road, bumped and pulled out, etcetera, etcetera; things as it were no longer remain symmetrical. I will have to mod the design to fit the other side as it appears to be near .425 inches offset from center of the role cage tube to the tapped holes in the column compared to the driver’s side. Maybe I will print the other one in Black or Red ABS plastic instead of the regular ivory color.

When I get my license up and running this weekend I will post some pictures of the CAD model. My main drive crashed and a new version of Creo Parametric 3.0 is out so I am in the process of upgrading and recovering from my SSD drive death.

3D printer we use:
http://www.stratasys.com/3d-printers/production-series/fortus-250mc

Yes that is my yellow Ghia in the Background

The print run on all these took 72 hours! And then 6 hours in the tank to dissolve all the support material.

3D printing or additive manufacturing
http://en.wikipedia.org/wiki/3D_printing
_________________
"Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind."
- Dr. Seuss
VW 181 Archive: https://sites.google.com/site/jeffgilleland/vw_archive
| _______
| |_______| '73 Thing "481"
| _\_\_|_/_/_
| |O||_4_||O|
| [ ]=====[ ]
http://vwthingregistry.com
https://doublecabshaka.wordpress.com

[shum]

3D printing is such interesting development, oh the possibilities!
Back about 10 -12 or so years ago I was invited to the NASA Marshall Flight Center in Huntsville were in a back room shop/lab I first saw a 3D printer, it was the size of a car and printed with a plastic/resin like material (simple forms). I got to go back three years running and each time sought out the lab with the printer, it was evolving quickly. By the third year it was down to the size of the one you posted the link to, but most impressive was that at that point it was printing with a metal like material and very complex forms. the object I observed was an adjustable crescent wrench that actually worked. The idea being that one could launch a printer into space (ISS) and then "print" parts as needed vs having to get one from earth.Maybe you could create the files to build a "thing" in space and it could be driven around on the moon. Actually, I would be really happy to just get quality parts here on earth!
_________________
57 rag top, 67 bug, 73 Thing
70 Bronco U14, 73 Bronco U15
61 R69S/2 BMW, 73 R75/5 BMW

[shum]

3D printing is such interesting development, oh the possibilities!
Back about 10 -12 or so years ago I was invited to the NASA Marshall Flight Center in Huntsville were in a back room shop/lab I first saw a 3D printer, it was the size of a car and printed with a plastic/resin like material (simple forms). I got to go back three years running and each time sought out the lab with the printer, it was evolving quickly. By the third year it was down to the size of the one you posted the link to, but most impressive was that at that point it was printing with a metal like material and very complex forms. the object I observed was an adjustable crescent wrench that actually worked. The idea being that one could launch a printer into space (ISS) and then "print" parts as needed vs having to get one from earth.Maybe you could create the files to build a "thing" in space and it could be driven around on the moon. Actually, I would be really happy to just get quality parts here on earth!
_________________
57 rag top, 67 bug, 73 Thing
70 Bronco U14, 73 Bronco U15
61 R69S/2 BMW, 73 R75/5 BMW

[citroen]

Nothing like using the company's toys I hope they don't charge by the hour on those parts if so they might be the most expensive parts on the thing

[Solomon Grundy]

Here are pictures of the Creo Parametric models.
The only hours our on me… But yes not cheap.
Consumables were probably less than $300.
More info later.

http://en.wikipedia.org/wiki/PTC_Creo

From nightmare to reality in just a few days.

The thin sketches, a circle and a rectangle, represent the areas of the 181 I was designing around; also known as top down design or a skeleton framework or part. The other thin objects represent the datum planes.

These models were created and then exported to an STL file then processed in the post printing software before being submitted to the machine. If anyone wants the Creo or STL files I would be happy to send it to you for free of course.

_________________
"Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind."
- Dr. Seuss
VW 181 Archive: https://sites.google.com/site/jeffgilleland/vw_archive
| _______
| |_______| '73 Thing "481"
| _\_\_|_/_/_
| |O||_4_||O|
| [ ]=====[ ]
http://vwthingregistry.com
https://doublecabshaka.wordpress.com

[Solomon Grundy]

When I designed this part it was with the idea that I could flip it over to use on the passenger’s side too. But that seems not to be the case. Obviously the precision drilled holes for the role cage are a little off and maybe the car has been off road a few times. Off by nearly half an inch... Fortunately it is parametric CAD model so I can easily update the original. I will be printing another one to complete the set. Perhaps I can show some of you at the So Cal classic weekend or at VTO events the weekend of June 13th and 14th.

Here is a picture of the model when I do the mesh for the STL output in PTC Creo Parametric to the 3D Printer post processing software. I thought it was sort of cool looking.

_________________
"Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind."
- Dr. Seuss
VW 181 Archive: https://sites.google.com/site/jeffgilleland/vw_archive
| _______
| |_______| '73 Thing "481"
| _\_\_|_/_/_
| |O||_4_||O|
| [ ]=====[ ]
http://vwthingregistry.com
https://doublecabshaka.wordpress.com

[Bashr52]

This post is right on time! We have been outsourcing all our 3D print work for the last couple years. We convinced upper management a few years ago to buy our own machine, and we budgeted for a stratasys. When it came time to pull the trigger, we were told no. I finally convinced everyone to let me order one of these on Tuesday.

It has a slightly larger capacity than the stratasys machine we were looking at, comes in at under $5000, and is one of the fastest machines in its class. I've got some sample parts and they look really good. One of them is the adjustable wrench shum was talking about.

I think some new air filter bases/tops would be a good project to break in the machine on

[Solomon Grundy]

Getting a good CAD jockey will make that machine shine.
Be mindful that the spools of material, I assume ABS, are sensitive to moisture. If you get them lying around too long they will cause fuzzy parts.
This is a neat tool to add to your design sweet. It is truly (AM) Additive Manufacturing. Not a panacea but just a nice extra too. Learn its parameters and it will put you ahead of the pack.
If you want my CAD files and know how to use Creo Parametric 3.0 I will send them to you. STL files won’t work so well because you will need to edit the object for your beast.

I have this part turned up to the highest resolution the 3D Printer has and a solid part to boot. ETA on the print job is 24.5 hours.
CAD Model data:
VOLUME = 8.1840671e+00 INCH^3
SURFACE AREA = 6.3047994e+01 INCH^2

For those wondering about the material cost for the average low end industrial grade 3D Printer; I have heard material cost estimates an average of $6 a cubic inch.

In the oven...

_________________
"Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind."
- Dr. Seuss
VW 181 Archive: https://sites.google.com/site/jeffgilleland/vw_archive
| _______
| |_______| '73 Thing "481"
| _\_\_|_/_/_
| |O||_4_||O|
| [ ]=====[ ]
http://vwthingregistry.com
https://doublecabshaka.wordpress.com

[Semper_Dad]

I think it's a great idea to tie the rollbar to the center doorpost. However, due to the different configurations of rollbars and their installation do you feel it's possible to come up with a universal bracket? Even original dealer installed bars had to have some variance in them. I really can't believe that each install will be identical.

Is it your intention to "cast" or "fabricate" the final product?
_________________
Walküre Restoration Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=737492

[Solomon Grundy]

I did figure that out quite quickly. Let’s see… how many types of roll cages are there and most of the cars are a little tweaked from use and age. So the variations are huge. When I was at the last show and checked my design on several other Things; none of them were even close.

The bracket I made helped stiffen that area quite a bit. Now the door closes much more soundly.

I will consider that a major design challenge and if I or anyone else comes up with a design idea please let me know.

Maybe we should start a thread on that if folks are clever enough. Get some basic parameters and get folks to post up some dimensions and we can all give it a shot. Could be a fun project for the group.
_________________
"Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind."
- Dr. Seuss
VW 181 Archive: https://sites.google.com/site/jeffgilleland/vw_archive
| _______
| |_______| '73 Thing "481"
| _\_\_|_/_/_
| |O||_4_||O|
| [ ]=====[ ]
http://vwthingregistry.com
https://doublecabshaka.wordpress.com

[Semper_Dad]

I was thinking in terms of a two part system where the "L" bracket and bar cradle are two different parts. User would then cut the "L" bracket to size, then weld the cradle to it.
_________________
Walküre Restoration Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=737492

[Solomon Grundy]

COOL. Make some measurements and take pictures of yours and sketch your idea up and I will make a CAD model.
_________________
"Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind."
- Dr. Seuss
VW 181 Archive: https://sites.google.com/site/jeffgilleland/vw_archive
| _______
| |_______| '73 Thing "481"
| _\_\_|_/_/_
| |O||_4_||O|
| [ ]=====[ ]
http://vwthingregistry.com
https://doublecabshaka.wordpress.com

[Bashr52]

[Semper_Dad]

I'm not an engineer, CAD geek, or even a fabricator but the way I see it is;

There are essentially 3 components to this bracket

1. The "mounting plate" (part that bolts to the door pillar)
2. The "saddle" (part that bolts to the rollbar)
3. The "bridge" (the part that joins the two)

Both the mounting plate and saddle are fixed in their design. They really don't change regardless of position of the rollbar. The saddle changes only in relation to the overall diameter (OD) of the rollbar that it's attaching to.

In my opinion, the "bridge" is what is what the focus needs to be on. That's the part that needs to be designed for the most flexibility. Could simply be a piece of flat or boxed stock joining the two other parts.

Certainly not as refined or elegant as Soloman's one piece design. I would have loved to see something like his design cast in aluminum.
_________________
Walküre Restoration Thread: https://www.thesamba.com/vw/forum/viewtopic.php?t=737492