flyrotary@lancaironline.net Mailing List Archive

Its pretty amazing what you can do with the proper 3D printing process. It can do some things easily that are very difficult and costly to try and machine. I recently used the 3D process to prototype some electronic enclosures – other more traditional methods would have cost me $700 – $1200 per prototype, using 3D I got them for $70.

My experience indicates that there are still limitations – the finish is somewhat lacking and reproducibility to the same precision also does not always work out. Any part of a model with an overhang generally has to have some sort of support (designed to be removed later) which can leave results that are somewhat unaesthetic looking. I imagine both have a lot to do with the cost and quality of the 3D printer.

But, for a casting of the size of a manifold the only problem I see is finding a 3D printer that can accommodate the size. But, giving how rapidly things are changing in the 3D printing world, its probably just a matter of looking.

Good Luck, Bob. I for one would be very interested in how your casting project turns out.

Edward L. Anderson
Anderson Electronic Enterprises LLC
305 Reefton Road
Weddington, NC 28104
http://www.andersonee.com
http://www.eicommander.com

From: Rob Bollinger

Sent: Thursday, May 01, 2014 9:50 PM

To: Rotary motors in aircraft

Subject: [FlyRotary] Re: Foundry Experience?

Hi Thomas,

Any news on the 20B manifold.

Robert Bollinger

On Fri, Dec 20, 2013 at 9:09 AM, Thomas Mann <tmann@n200lz.com> wrote:

Well .... yet another new development.

I'm sure that many of you are familiar with the 3D printing process.

I was contacted by a foundry supply company. After a bit of chatting he suggested that I create the manifold in 3D CAD software and have them 3D print it in wax, ready for casting.

The process even takes into consideration the shrinkage of the particular metal you are pouring. I believe Aluminum is 1.3% (or there about.)

I was already modeling this in 3D with Rhino but I had my CNC hat on, not my Investment Casting hat. I just could not imagine how a CNC could handle this (plus that would be very expensive.)

Anyway, if this does work out, once I have a working prototype, (and if it is cost effective) I can start cranking these out at will.

I'll be moving on to the air-box (cool side intake) once this is done.

T Mann

Sent from my ASUS TF600T using Windows 8
50% Brighter than any iPad

Robert Bollinger

MR722 MUM

Fairfield, IA 52557

(641)919-3213

rob@mum.edu

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