3D Printed Customized Automotive Components

It could be an understatement to say that Michael O’Brien likes vehicles. Take one take a look at his Instagram, and you will see what I imply. He is absolutely immersed within the automotive trade; being lead engineer on the Roadster Store, I would think about that you just’d should be.

Once we found that O’Brien (aka Magic Mike) was utilizing 3D printing to assist design and manufacture customized equipment for vehicles, we knew he needed to be featured as our December Hacker of the Month. 

3D printed customized gauge cluster for O’Brien’s Datsun 620

O’Brien was launched to 3D printing whereas attending Iowa State College, the place he had the chance to work together with early FDM machines for speedy prototyping and half growth. He just lately bought a LulzBot Mini for his private tasks, which has helped advance the visions he has for his designs. “Stable modeling has developed into such a terrific software and group through the years,” mentioned O’Brien, “however the revolution in reasonably priced and out there 3D printing has lastly allowed me to take complicated components I design that may usually be tough and dear to provide, and make them a practical ultimate product with nice high quality and entry.”

Printing away on the LulzBot Mini

O’Brien is at the moment engaged on components and parts for his Datsun 620 challenge, and you’ll comply with the progress right here. “For each my very own work and our work at The Roadster Store, 3D printing has allowed us to step out of the standard manufacturing strategies and design components and merchandise at a significantly quicker and extra complicated degree,” he explains.

Most of the components that O’Brien designs and prints are car parts that can’t be discovered or are very costly to copy, so with the assistance of 3D printing and Solidworks, he’s in a position recreate iconic options for traditional vehicles. “It is easy to design a loopy complicated element when you have the expertise, however most would agree that truly taking the digital imaginative and prescient and making a bodily element is at all times the toughest half,” he states, including that, “3D printing actually permits me to precise my creativity and let my designs present within the bodily realm, permitting lots of boundaries to be faraway from conventional manufacturing design.”

3D Printed offset-angled, 3 tier swap assemblies

O’Brien primarily makes use of HIPS filament as his go-to materials. “I’ve discovered that it is warping and delaminating properties are the perfect I’ve used,” explains O’Brien, including that “ABS filament could be an in depth second, for these components that require the power and end-use properties on a component that shall be utilized in automotive purposes. I additionally use T-Glase for any clear half designs.”

Once I assume clear T-Glase and vehicles, my thoughts instantly goes to headlights and tail lights, which is seemingly what O’Brien has been experimenting with. “The great factor about printing with T-Glase for lighting is that the interior layering results of the print act as diffusion materials,” he explains, clarifying that “when designing lights (particularly tail lights), it is very important embody diffusing designs and shapes with a number of angle altering aspects to assist unfold and scatter the sunshine right into a not-concentrated bloom of sunshine, and the interior ridge traces and “imperfections” left from 3D printing the clear supplies do an excellent job of this.” 

He used this similar design factor for the illuminated rings round his Datsun 620’s swap legend plates, which you’ll see under. “Since I used to be utilizing LED lamps which have a really concentrated and slender mild beam, I used the uncooked T-Glase printed rings with their ridge traces assist diffuse and scatter the LED mild to a extra uniform glow,” mentioned O’Brien.

3D printed swap legend plate for the Datsun 620

Illuminated swap legend plate

I requested O’Brien if he had any ending methods for his prints which can be used past prototyping, and that truly make it on a automotive – he is already a 3D printing purist: “for me, the terracing and layering results left on 3D prints are a part of the enjoyable of 3D prints. In a nerdy approach, it exhibits folks that the half is certainly 3D printed, and I believe showcasing the pure tool-path traces and layers from the half speaks volumes to the standard of the printer and supplies used, so typically I don’t post-finish a lot of my components.” O’Brien is a true maker showcasing each medium used to create his Datsun 620 construct.

Half on the Inferno 1969 Camaro designed by Chris Gray.

At present, O’Brien has roughly fifty 3D printed parts on his Datsun 620 construct. “I would count on the variety of printed components within the ultimate truck to be within the couple a whole lot at the least,” exclaims O’Brien, explaining that, “wiring harness ends, bulkheads, and clips and clamps to carry issues into place shall be used – emblems throughout the truck, door deal with bezels, tail lights and housings, mirror bases and stems, fuse holders, gasoline and brake plumbing clamps and holders….. there are such a lot of concepts working via my head that I do know 3D printing is the reply for!”

Try extra of O’Brien and the Roadster Store’s tasks on their website and his Instagram. Under are some photographs of the Roadster Store’s most up-to-date construct: the Inferno 1969 Camaro, which just lately took the Goodguys Rod & Customized Affiliation ‘Gold’ Award on the The SEMA Present.

3D printed backing plates on the Inferno Camaro, designed by Chris Gray.

Last product of the 3D printed backing plates on the Inferno Camaro

The Inferno 1969 Camaro in all it is glory

Wish to be our subsequent Hacker of the Month? E-mail [email protected], and inform us about your 3D printed creation – you might be featured in our subsequent e-newsletter. Hacker of the Month wins 3 free spools of PRO Sequence PLA or ABS filament to additional their pursuit of 3D printing greatness.