RE: Can the new XL use metal for printing?
Thanks MileHigh3Der
But no room for any hardware as a mechanical holding part. The thickness has to be thin, like less than 1/32" inch, or 0.795mm
RE: Can the new XL use metal for printing?
The product is 1/32" thick, from 1 1/2" - 2 3/4" in width and from 3" - 9" in length and is of a wavy shape in stainless steel.
I certainly do not know what exactly you are trying to design, but based on the dimensions and general shape it seems that your product will be acting as some sort of spring or dampener. I may be corrected, but I am not aware of any plastic that is going to have a spring-factor in the same realm as metal.
Also, if there is any potential safety hazard with this product if it fails, I would suggest you strongly consider against FDM printed plastics. The quality differences between prints could vary significantly and have a major impact on the load carrying capacity of your product. A misstep on the extruder could create a little void in your part, you may of had bonding issues with your infill due to an unexpected draft which resulted in a weaker-than-expect part and you would likely never be able to notice.
If your product does allow for FDM printing to be an option, you will have to pay close attention to the orientation of you part. Infill and z-axis orientation plays a significant role on the strength of a part depending on the direction a load is applied. CNC Kitchen has some videos describing this in more detail.
Also, depending on the quantities, outsourcing the product is likely a viable option, especially for a product/market test run. There are many different manufacturing methods to make products: CNC, EPDM, Injection Molding, Lost-wax, powdered metal (printing or pressing), etc. Google and look for all the options, reach out to local manufacturing companies and ask them about their process. When you find a potential option, get an NDA (non-disclosure agreement) with the company and start discussing details. They will be able to guide you to the best option typically.
RE: Can the new XL use metal for printing?
That’s like .8mm thick, so 4 layers at .2? I’d want at least three layers to get some kind of cross-hatch going. Maybe a lot of perimeters?
If springy is criteria, then fiber filled will work against you.
You said 300lbs (static or dynamic?) from something 1/32(.8mm) thick…. Nylon? Unobtanium 😉
Definately are could use some post processing/heat-treating to get the most strength and layer adhesion.
Interesting problem, going to be an even more interesting solution…
RE: Can the new XL use metal for printing?
It might be best for you to contract with a service bureau like Xometry.com . You should be prepared to provide drawings, functional specs, & descriptions. If you're worried about sharing your idea, you can have them sign an NDA. They're used to that.
I see now how important the details are. Well obviously I don't wish to share an idea that I am working on, but let me get more specific. The product is 1/32" thick, from 1 1/2" - 2 3/4" in width and from 3" - 9" in length and is of a wavy shape in stainless steel. It should not be able to flex much if at all, that's important to the function. I'm sorry I do not have the head to calculate the stress per sq in. I can tell you that of a sudden the stress can go from 4-12lbs to 300lbs, thus load would be dynamic in reference.
Injection molding requires a $40-$80k die/tooling cost? Forget that then since my numbers are too low to cover that cost as is my sales projections at this time
Which by your explanation, which I very much appreciate, production would be far less than 50k pieces
Whatever you find to do with your hands, do with all your might!
RE: Can the new XL use metal for printing?
Yes in a fashion, it will be subject to torsion across the width and the length, from any direction available as the design allows. It will also be subject to longitudinal forces and of a sudden.
No safety hazard at failure, would be a longshot, possible but not likely.
My first step is to find a facility, I was told Shapeways?, for a prototype since they could do the CAD drawings according to my dimensions. Trouble with theat is you cannot speak to anyone there, and I cannot imagine writing down all the details, that would be so much easier to speak and then provide a detailed drawing, with the use of Free sketchup, that I have not much use with yet
RE: Can the new XL use metal for printing?
Don't know if somone mentioned it, but it sounds like something that could be laser/water-jet cut out of metal.
RE: Can the new XL use metal for printing?
Not sure. The project needs to be very thin and slightly flexible such as in spring steel, but in stainless or another very tough material to be able to hold up to 300lbs of immediate force applied in any direction