Starting on a new small project now, this one is for internal use. We have a DMU50 5 axis CNC machining centre and it’s always been troublesome. When it works it’s great but it breaks down very often and the support to solve these problems locally is pretty inadequate, as an example we have had 1 problem from day one that has still not been solved (we have a dodgy fix for it, and now it’s out of warranty I don’t want to spend more on it. I actually emailed DMG in Germany about this, they didn’t bother to acknowledge or reply.
Not only that but what they charge is also outrageous, case in point this plastic tool clip, it would cost less than A$1 to make as it’s produced via an injection mould yet they was to charge me ~A$100 per piece!! So I’ve started modelling this up in a way that’s suitable for 3D printing.
What I’ve found/think so far is that the material is nylon which is OK as you can print in this material but it requires some special extra’s such as a heated bead and a higher than usual printing temperature (~240c). I found a good layout for SK40 on the internet but found that it needs some reworking for 3D printing as printing upwards on an angle can cause the surface to distort. I tried increasing the bottom angle but it didn’t help so I went back to the 60 degrees included angle and just slowed the printer down to 80% and it came out a lot better.
The other issue currently is I do not have a nylon printer, only a PLA on. PLA is strong enough to use as a clip but has very low elongation 6% where are nylon has lots. I have tried making the tool opening much larger but almost any bending moment with PLA causes it to crack.
With the main race correct though I will finish the model off and get some local company to print it in nylon, if that works that I will get something like the Ultimaker 2+ with the bed gear and make them myself after.
When completed I will also give everyone the 3D FOC so they too can make this inexpensive part themselves.