PaperModelers.com

Go Back   PaperModelers.com > Papermodelers' Bar and Grill > Other Things We Do & Make

Reply
 
Thread Tools Display Modes
  #1  
Old 12-24-2023, 03:47 PM
mbauer's Avatar
mbauer mbauer is offline
Member
 
Join Date: Apr 2009
Location: Nikiski, Alaska -9UTC/-8UTC DSTime
Posts: 4,022
Total Downloaded: 27.71 MB
Going to the Dark Side: 3D Printing

Hello Everyone,

Took a big step last week for my retirement plans. For years been planning to purchase a 3D printer and open a business "printing things for people".

Technology has improved the type of filament you can print with.

Want to print something using different metals?
1) Tungsten is available
2) Titanium
3) Inconel
4) Aluminum
5) Mild Steel

Are just a few.
You do need to cook the item in a kiln to debind/sinter the parts into pure metal.

What I bought was the PLA blend of carbon fiber filaments.

After years and years of playing/designing paper models my end goal has always been to create my own design and build the airplane, ultimately flying it.

Plan was full size EPS foam model layering fiberglass/carbon fiber over the top to create the aircraft. Foam for this is between $5000-$6500 before shipping. Fumes and cost of resins for using the cloth is extremely high.

On the side without much mention is a project that will become an electric powered airplane with the name Danger High Voltage. 360Volts is pretty high.

A Chevy Volt car will be the donor power supply. Why a Volt? Because the hybrid system is a series, just like train locomotives.

The ICE (Internal Combustion Engine) is a generator and does not supply power to the early model Volts.

What electric plug in vehicles lack? is range.

The Chevy volt calls the ICE a "Range Extender" meaning you can fill up with gas at the local pimps if the commercial electric charger isn't working. on 7.9 gallons it goes 420-miles with batteries fully charged.

After checking 3D printers, you can get a fairly large size printers now for around $2500 for 300mm x 300mm x 300mm.

Not big enough to print a full size airplane......

Found one that can and bought it:
Tronxy WEHO 1000-16 2E print head= $3850.00

Size of print? 1000mm x 1000mm x 1600mm H ( 39.37" x 39.37" x 62.99")

The frame will barely fit under my ceiling here at home.

Bought the 2-into-1 print head. Will allow using titanium for spars and longerons while the carbon fiber shell is being printed.

150hp Electric motor available full time to power, over 200hp available for take-off when the computer switches the generator to help power the drive wheels for acceleration and hills.

Propeller at first to learn if it will fly, then EDF conversion.

Printer should arrive 2nd week of January. Free shipping.

Can print 36" Diameter fuselage in 5ft interlocking sections.

Titanium is expensive stuff, carbon fiber is too-1kg spool is $113. Titanium is 4-times as much.

Got different filament heading this way: two different brands of carbon fiber PLA mix. and a common PLA spool.

Need to be careful with the filament; needs heated/dry storage boxes as it will suck up water in the air and destroy a print. Metals have a very short span between opening and printing.

Best regards,
Mike Bauer

Last edited by mbauer; 12-24-2023 at 03:53 PM. Reason: Plan was
Reply With Quote
Google Adsense
  #2  
Old 12-24-2023, 03:53 PM
airdave's Avatar
airdave airdave is offline
Member
 
Join Date: Apr 2009
Location: Ontario Canada
Posts: 14,246
Total Downloaded: 257.44 MB
Quote:
Not big enough to print a full size airplane......
but what about a Lamborghini?
3D Printing a Lamborghini Aventador! - YouTube

__________________
SUPPORT ME PLEASE: PaperModelShop
Or, my models at ecardmodels: Dave'sCardCreations
Reply With Quote
  #3  
Old 12-24-2023, 03:56 PM
mbauer's Avatar
mbauer mbauer is offline
Member
 
Join Date: Apr 2009
Location: Nikiski, Alaska -9UTC/-8UTC DSTime
Posts: 4,022
Total Downloaded: 27.71 MB
Do you prefer:

Titanium or carbon fiber for the construction?

5ft long x 40" W sections.... which should work for the side panels. Front trunk cover and engine cover might need to be two piece.

3D hand held scanner for around $1000

3D Printer: Priceless

Software can now print from jpeg, png, bmp etc..

They do have a 2400mm wide printer if you really want to print the car. What frame are you going to use? Chevy Fiero? or other mid-engine? Used to drive a Porsche 914 with a mid-engine. It was fun right up until you broke the rear-end loose on ice. It would spin a 360 really fast like a VW bug of old.

Mike

Last edited by mbauer; 12-24-2023 at 04:08 PM. Reason: etc
Reply With Quote
  #4  
Old 12-24-2023, 04:30 PM
airdave's Avatar
airdave airdave is offline
Member
 
Join Date: Apr 2009
Location: Ontario Canada
Posts: 14,246
Total Downloaded: 257.44 MB
Not trying to sidetrack, but that story about the Lambo is quite interesting when you consider he used a much smaller 3D printer.
The body is broken down into sections, which are then broken down into smaller parts that can be printed on his machine.

The chassis is completely scratch built to Lambo specs, like the rest of the car.
Lamborghini (the company) even showed their support and gave him some parts.

Imagine if you copied an existing aircraft...maybe the original manufacturer would throw support into the project?
Doesn't Lamborghini make Jets? I know Honda does.
__________________
SUPPORT ME PLEASE: PaperModelShop
Or, my models at ecardmodels: Dave'sCardCreations
Reply With Quote
  #5  
Old 12-24-2023, 06:23 PM
mbauer's Avatar
mbauer mbauer is offline
Member
 
Join Date: Apr 2009
Location: Nikiski, Alaska -9UTC/-8UTC DSTime
Posts: 4,022
Total Downloaded: 27.71 MB
Quote:
Originally Posted by airdave View Post
Not trying to sidetrack, but that story about the Lambo is quite interesting when you consider he used a much smaller 3D printer.
The body is broken down into sections, which are then broken down into smaller parts that can be printed on his machine.

The chassis is completely scratch built to Lambo specs, like the rest of the car.
Lamborghini (the company) even showed their support and gave him some parts.

Imagine if you copied an existing aircraft...maybe the original manufacturer would throw support into the project?
Doesn't Lamborghini make Jets? I know Honda does.
Pretty sure the FAA would have something to say about scanning and printing an existing aircraft.

SR71 does come to mind though. Wonder how long it would take to scan the M21 at the Seattle Museum of Flight? Close enough to a SR71 for printing purposes....

Besides the Ford GT 40 would be much more to my liking.

Mike
Reply With Quote
Google Adsense
  #6  
Old 12-24-2023, 10:49 PM
murphyaa's Avatar
murphyaa murphyaa is offline
Member
 
Join Date: Jul 2007
Location: Somewhere out there
Posts: 6,604
Total Downloaded: 313.47 MB
Send a message via Yahoo to murphyaa Send a message via Skype™ to murphyaa
3D printing a SR-71 could get pricey.
__________________
My New Website: https://murphs-models.com/
Visit my Youtube Channel
Reply With Quote
  #7  
Old 12-25-2023, 08:01 AM
birder's Avatar
birder birder is offline
Member
 
Join Date: Jul 2007
Location: Eastern Washington
Posts: 4,979
Total Downloaded: 86.00 MB
My gosh Mike those are incredible plans best of luck!!
__________________
regards Glen
Reply With Quote
  #8  
Old 01-09-2024, 09:59 PM
mbauer's Avatar
mbauer mbauer is offline
Member
 
Join Date: Apr 2009
Location: Nikiski, Alaska -9UTC/-8UTC DSTime
Posts: 4,022
Total Downloaded: 27.71 MB
Initial Concept Drawing

All of the designs I've done to date for this project have been 2-seat versions.

Vasyfan has an EDF that will work for a single seat version.

VF-570 Nacelle

VF-750 Specs
22.44" Diameter Fan (my RV6 prop is 71" Diameter)
Exhaust speed: 223 mph (RV6 maximum speed 220mph)
Static Thrust: 382lb (RV6 around 600-700lbs)
Fan Maximum RPM: 6000rpm (RV6 and most airplanes 2700max. RPM)

Static Thrust will get me moving, flying speed requires Dynamic Thrust or the fans exhaust speed. Actual flight speed will be the 223mph minus all drag of aircraft. Quick explanation: 223mph - 20mph in drag = 203mph max.

Initial Aircraft specs:
Length: 18ft 2-1/4" (RV6 = 20ft)
Wingspan: 13ft 4-7/8" (RV6 = 23ft)
Est. Weight: 1200lb GW (have to stay below this weight for the EDF to be able to work) RV6-weighs 1065lbs empty / Gross Weight is 1800lbs.

Cost for this system is less than half what a Lycoming 0320 airplane engine costs. $23,000 USD for fan and ESC.

Drew up a completely new design for this.
Going to the Dark Side: 3D Printing-2024-danger-high-voltage-concept-drawing.jpg

Concept drawing showing some of the particulars, fuel, battery, oh and the generator-why only pack batteries around that can maybe get you from one end of the runway to the other?

This project started with my first computer purchase in 1985-MACINTOSH Plus:
1) Went to a 2-year program for learning to use AutoCAD to draw the project with (1999-2001 training)
2) Design all kinds of flying models to determine what works-what doesn't-lots of those projects are here
3) Waited since 2009 when I was selling EDF SR71 on Ebay for the EDF market to come up with a workable EDF-That just happened
4) OCT. 2008 Elemental Finite Analysis design course for aircraft structure in Montery, CA
5) Medical issue speeding up retirement plans. Found out I have Squamous Cell Carcinoma in my right upper jaw. For now just in my jaw, not in lymph nodes or anywhere else-got lucky we found it soon enough-Feb 6th surgery. Expecting a full recovery-this has given me some serious reasons to get this long time project moving.

BTW-The money has been sent for the fan: Today

Mike

Last edited by mbauer; 01-09-2024 at 10:26 PM. Reason: explain flying speed
Reply With Quote
  #9  
Old 01-09-2024, 11:15 PM
murphyaa's Avatar
murphyaa murphyaa is offline
Member
 
Join Date: Jul 2007
Location: Somewhere out there
Posts: 6,604
Total Downloaded: 313.47 MB
Send a message via Yahoo to murphyaa Send a message via Skype™ to murphyaa
Kinda has an F-16XL vibe to it.
__________________
My New Website: https://murphs-models.com/
Visit my Youtube Channel
Reply With Quote
  #10  
Old 01-10-2024, 12:34 AM
mbauer's Avatar
mbauer mbauer is offline
Member
 
Join Date: Apr 2009
Location: Nikiski, Alaska -9UTC/-8UTC DSTime
Posts: 4,022
Total Downloaded: 27.71 MB
Cranked Arrow Wing

Love the F-16XL cranked arrow wing design. Hi lift/low drag.

Several future aircraft designs are using versions of it. One that is a lifting body:
Going to the Dark Side: 3D Printing-pict0698.jpg

Already modified the wing shape to be a higher aspect ratio, probably will modify again once flight testing of a scale model starts.

Mike
Reply With Quote
Google Adsense
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump


All times are GMT -6. The time now is 06:00 AM.


Powered by vBulletin®
Copyright ©2000 - 2024, Jelsoft Enterprises Ltd.

Parts of this site powered by vBulletin Mods & Addons from DragonByte Technologies Ltd. (Details)
Copyright © 2007-2023, PaperModelers.com