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Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic
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Solomon Grundy
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PostPosted: Sun Jan 22, 2017 10:41 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

New color design by Heather in Minnesota

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and on her car.

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Welt
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PostPosted: Fri Jan 27, 2017 9:57 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Solomon Grundy wrote:
Welt, that is so cool. Glad you are having fun and sharing your experience with the group. I think that looks great! If time allows I may try that myself. Can't wait to see some of the first molds. Very Happy


IMO casting in general is often forgotten or even somewhat looked down upon as a process, so I think it's fun to open peoples' eyes on what they are easily able to do if they just want to. Writing about it all is half the fun too. The following is not really possible for most people though, but the plaster mold part should be simple enough.

Surfaces lightly sanded, smooth Very Happy
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This geometry works quite nice, but no rounds or drafts makes the wax stick to vertical surfaces. Not such a big deal in this case, but if one would design a part just for this process these features would aid a lot.
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Multiple pieces are asembled, a complete wax pattern.
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In this process, the wax pattern is dipped into ceramic slurries (fine ceramic powder+colloidal silica) and stuccos. A face coat of zirconia can be seen here. Multiple coats of coarser molochite after that.
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After each coating step, the molds are left to dry. After enough wall thickness is achieved, molds are dried for a longer period. Wax removal is done by flash firing in this case. Furnace temp. set at around 650C and molds are put in. The temperature is so high that the wax has no time to expand and break the molds in their green state. After all wax has dripped out, furnace temperature is increased and the molds are sintered for a certain period of time.
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Wax will either flow out or burn, so only a clean hollow cavity is left.
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Sintered, high temp. molds would be good to cast straight up, but these will wait a while for something more important to come along to justify melting a full crucible of aluminium. Placed in a preheating furnace here.
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This is technique is easily available to all, so why not make one for show. Simple castign channel, part and a small plastic bucket.
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Personally, I'm not too fond of plaster casting as it requires a much more careful heating control. This mold plaster was mixed in 1.4:1 ratio to water and just poured inside the bucket. Plaster is somewhat similar to the polyurethane I used in the earlier steps as the mixed potlife is quite short. Also, old plaster in mixing container will start the hardening reaction super quick, so clean equipment is a must.
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These will be cast one day, so I'll post pics of the results when that happens.
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Solomon Grundy
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PostPosted: Fri Jan 27, 2017 2:41 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

WELT, that is awesome!!!
If you want any CAD modifications like a draft or other such changes so they pop out of the mold better, please just give me shout out. I can easily update the design for you. CAD is actually my strongest skill set.
I have just made a recent design change because some of the M4 metal inserts broke through on my last run; so I increased the overall height to compensate. It is so slight probably no one will know.
Next run I will start adding a serial numbers too them, as it seem 181 Volks enjoy this little project. Each CAD model will start being uniquely individualized with embossed numbers in a slightly different place with different font types & size on the back of each, for that special touch.

BTW, can I get on the list for one of those bad boys for my car? Cool
https://181thing.wordpress.com/
_________________
"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|
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Welt
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PostPosted: Mon Jan 30, 2017 8:54 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Solomon Grundy wrote:
WELT, that is awesome!!!
If you want any CAD modifications like a draft or other such changes so they pop out of the mold better, please just give me shout out. I can easily update the design for you. CAD is actually my strongest skill set.
I have just made a recent design change because some of the M4 metal inserts broke through on my last run; so I increased the overall height to compensate. It is so slight probably no one will know.
Next run I will start adding a serial numbers too them, as it seem 181 Volks enjoy this little project. Each CAD model will start being uniquely individualized with embossed numbers in a slightly different place with different font types & size on the back of each, for that special touch.

BTW, can I get on the list for one of those bad boys for my car? Cool
https://181thing.wordpress.com/


Doesn't really matter at this point, so no need to do any changes. Sure, I'll send you one from this batch if you'll reimburse shipping costs.
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Welt
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PostPosted: Wed Feb 01, 2017 9:59 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Casting day came a little early this time.

Image may have been reduced in size. Click image to view fullscreen.


Most of these had one cog tooth missing. Looks like one of the "knobs" block wax injection somewhat and air is trapped inside. Thus, slurry penetrates into the air filled cavities. That combined with the fact that those little holes are hard to fill with slurry and stucco -> parts of the mold might break and pieces will rattle inside where there should be metal.
Image may have been reduced in size. Click image to view fullscreen.


That's why I filed the knobs down and started to do small air channels. Will experiment some more when I'll have spare time. Next ones will certainly be better Very Happy
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Solomon Grundy
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PostPosted: Fri Feb 03, 2017 12:36 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

I would be more than happy to do so. Thank you so much.
No rush just let me know how much. I will PM you soon.
These look awesome.
Welt wrote:
Solomon Grundy wrote:
WELT, that is awesome!!!
If you want any CAD modifications like a draft or other such changes so they pop out of the mold better, please just give me shout out. I can easily update the design for you. CAD is actually my strongest skill set.
I have just made a recent design change because some of the M4 metal inserts broke through on my last run; so I increased the overall height to compensate. It is so slight probably no one will know.
Next run I will start adding a serial numbers too them, as it seem 181 Volks enjoy this little project. Each CAD model will start being uniquely individualized with embossed numbers in a slightly different place with different font types & size on the back of each, for that special touch.

BTW, can I get on the list for one of those bad boys for my car? Cool
https://181thing.wordpress.com/


Doesn't really matter at this point, so no need to do any changes. Sure, I'll send you one from this batch if you'll reimburse shipping costs.

_________________
"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
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GI Joe
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PostPosted: Sat Feb 04, 2017 8:32 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Welt,
I too would like one of these early run emblems! Flaws and all, I'm a sucker for the unique!!

I'll PM you details for shipping!

Thank you!


Solomon Grundy wrote:
I would be more than happy to do so. Thank you so much.
No rush just let me know how much. I will PM you soon.
These look awesome.
Welt wrote:
Solomon Grundy wrote:
WELT, that is awesome!!!
If you want any CAD modifications like a draft or other such changes so they pop out of the mold better, please just give me shout out. I can easily update the design for you. CAD is actually my strongest skill set.
I have just made a recent design change because some of the M4 metal inserts broke through on my last run; so I increased the overall height to compensate. It is so slight probably no one will know.
Next run I will start adding a serial numbers too them, as it seem 181 Volks enjoy this little project. Each CAD model will start being uniquely individualized with embossed numbers in a slightly different place with different font types & size on the back of each, for that special touch.

BTW, can I get on the list for one of those bad boys for my car? Cool
https://181thing.wordpress.com/


Doesn't really matter at this point, so no need to do any changes. Sure, I'll send you one from this batch if you'll reimburse shipping costs.

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Solomon Grundy
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PostPosted: Sun Feb 19, 2017 11:57 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

More fun New home print in Silver PLA. Scaled down for testing.

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_________________
"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"
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| |O||_4_||O|
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Solomon Grundy
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PostPosted: Sun Feb 19, 2017 12:15 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Being I had one batch break though when melting the metal inserts in I increased the height slightly on the CAD file to mitigate that issue.
Here is a link to the new STL file for those that would like to use it.
BTW: Units of this STL were done originally in Imperial Inches,not Metric.
https://goo.gl/bepaFs
Here is one in metric units.
https://goo.gl/L5bmn2

Enjoy,
_________________
"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|
| [ ]=====[ ]
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cwatts
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PostPosted: Sun Feb 19, 2017 6:03 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Hi Guys

My company has recently acquired a 3d printer - so naturally looking to print the KDF badge. When I downloaded the .stl file and gave it to the cad guy he told me that the overall size was tiny. So I'm after the diameter of the badge to adjust the .stl file? Anyone know that measurement?

Campbell
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PostPosted: Mon Feb 20, 2017 7:06 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

cwatts wrote:
Hi Guys

My company has recently acquired a 3d printer - so naturally looking to print the KDF badge. When I downloaded the .stl file and gave it to the cad guy he told me that the overall size was tiny. So I'm after the diameter of the badge to adjust the .stl file? Anyone know that measurement?

Campbell


What slicing software are you using? Mine has an option to scale MM to IN, the software may be interpreting the part in the wrong units.
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PostPosted: Tue Feb 21, 2017 11:05 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Welt wrote:
Casting day came a little early this time.

Image may have been reduced in size. Click image to view fullscreen.


Most of these had one cog tooth missing. Looks like one of the "knobs" block wax injection somewhat and air is trapped inside. Thus, slurry penetrates into the air filled cavities. That combined with the fact that those little holes are hard to fill with slurry and stucco -> parts of the mold might break and pieces will rattle inside where there should be metal.
Image may have been reduced in size. Click image to view fullscreen.


That's why I filed the knobs down and started to do small air channels. Will experiment some more when I'll have spare time. Next ones will certainly be better Very Happy
Image may have been reduced in size. Click image to view fullscreen.


Applause
hey Welt,
Very nice! I love seeing the "process" photos, please let us know when the finished product is ready!

T
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Welt
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PostPosted: Tue Feb 21, 2017 12:26 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

GI Joe wrote:
Welt,
I too would like one of these early run emblems! Flaws and all, I'm a sucker for the unique!!

I'll PM you details for shipping!

Thank you!

Sure, already sent two to US last week. If you want one or two of these first ones, PM away.

doublecanister wrote:

hey Welt,
Very nice! I love seeing the "process" photos, please let us know when the finished product is ready!

T

I'll need to demo the lost-wax process with magnesium in some time. Could fit a few of these too in there Idea
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Solomon Grundy
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PostPosted: Tue Feb 21, 2017 9:59 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

cwatts wrote:
Hi Guys

My company has recently acquired a 3d printer - so naturally looking to print the KDF badge. When I downloaded the .stl file and gave it to the cad guy he told me that the overall size was tiny. So I'm after the diameter of the badge to adjust the .stl file? Anyone know that measurement?

Campbell


Sorry about the barbaric Imperial units, I blame the Limeys. Cool
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BTW: Units of this STL were done originally in Imperial Inches,not Metric.
STL file in Inches: https://goo.gl/bepaFs
Here is one in metric units.
STL File in Metric: https://goo.gl/L5bmn2
_________________
"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
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Solomon Grundy
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PostPosted: Sat Feb 25, 2017 12:56 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

What is really inside these fun 3D Printed items! Yes a cool honeycomb lattice structure...
Some prototypes:
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_________________
"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
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Mr. Panda
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PostPosted: Tue Feb 28, 2017 2:37 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

I got mine!

Thanks a lot, I'll paint it and post pics later.

Added to my VW Thing stuff.
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Solomon Grundy
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PostPosted: Thu Mar 02, 2017 10:54 pm    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Welt Rocks! Cool
I am honored and flattered that others are enjoying this fun project.
Just got a nice delivery from Finland + Thanks
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_________________
"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
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Welt
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PostPosted: Tue Mar 07, 2017 8:15 am    Post subject: Re: Custom 181 hood KDF emblem, CAD to 3D Printed in ABS plastic Reply with quote

Sweet, seems that the shipment arrived in one piece!

While cooking another mold, tried detailing one from the first. Looks quite nice when you don't look too closely on it Laughing

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