Search found 44 matches

by caxton3d
Wed Jan 03, 2018 12:07 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

Vicky, here are links so that you can download load the .STL and .gcode files for the crankcase. (If anyone else would like to look at these files, feel free to do so). http://www.dennisfire.co.uk/timing%20side.zip If you look at the post from Daws on this thread I am not alone in finding difficulty...
by caxton3d
Wed Jan 03, 2018 11:48 am
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

Daws, after the crankcases comes the really interesting bit - A new cylinder barrel with four side transfer ports rather than the standard two side ports. That should test the printer! I am posting a link for Vicky with the .STL and .gcode for the crankcase if you want to have a look at it a bit mor...
by caxton3d
Wed Dec 27, 2017 9:32 am
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

Vicky, If you take a look at the screen shot of my settings you will se that I do have dense support turned on. Rather than have line infill I usually run with the cross hatch infill as this is stronger. Along with many other people I find that the line support is easily damaged as the print nozzle ...
by caxton3d
Tue Dec 26, 2017 9:59 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

This is a 1970 vintage Greeves Oulton 350cc two stroke racing motorcycle. http://www.dennisfire.co.uk/agr1.jpg These are the crankcases. There is a weakness around the top flange where the cylinder barrel bolts on. I need to cast new crankcases with a stronger flange. http://www.dennisfire.co.uk/agr...
by caxton3d
Tue Dec 26, 2017 9:31 am
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

StickShifter, I love the look of your cylinder head,. It will be no mean feat to machine it from solid. Do you have a 5 axis mill to get into the ports? I agree with you about the problems of removing the support material and the quality of the surface finish once the support is removed. I have a cr...
by caxton3d
Sun Dec 17, 2017 9:26 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

Stickshifter and Daws, GOOD! More converts to printing patterns for metal casting! I would love to see your results so don't forget to post some pictures. The main thing which I think is essential is that after the pattern is printed you should give it a couple of coats of 'Pattern Coat' which is an...
by caxton3d
Wed Nov 08, 2017 7:20 am
Forum: User's Gallery
Topic: Print Misalignment
Replies: 3
Views: 749

Re: Print Misalignment

I had this identical problem with the Raise printer after just a few days of use. The flexible coupler between the axis drive motor and belt shaft was loose. A two second fix with a hex key.
by caxton3d
Mon Nov 06, 2017 10:59 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

Vice Chief, it is nice to know that I am not alone in thinking that the Raise printers have a future in the Engineering Sector. They just need to push more in that direction. I am based in the U.K. and use the 'Bridport Foundry' ( you can easily find their website ). They are a small family run foun...
by caxton3d
Fri Nov 03, 2017 5:53 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

ABH, thank you for you kind words. When I see Raise promoting a competition for the best printed Halloween mask I just wonder whether they have their marketing strategy all wrong. It seems that they are promoting their printers as 'toys' to print more 'toys'. When I suggested to an Engineering Direc...
by caxton3d
Thu Nov 02, 2017 11:29 am
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

We are back to pattern printing. This time it is for a 'spider' which forms part of a flexible coupling linking the gearbox to the rear wheels. This is the drawing for the part. Draft angles of 2 and 5 degrees have been included to make the pattern easier to withdraw from the sand. http://www.dennis...
by caxton3d
Tue Sep 26, 2017 7:28 pm
Forum: User's Gallery
Topic: Single extruder multiple color using the Mosaic Palette
Replies: 101
Views: 16447

Re: Single extruder multiple color using the Mosaic Palette

I would have to disagree with Jetguy saying that you cannot print PLA with the cover on for long periods. I have printed parts taking over 80 hours with the lid on and have not experienced problems due to excessive temperature. Of course the ambient temperature must be so some significance. In my pr...
by caxton3d
Mon Sep 25, 2017 12:57 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

These are the castings back from the foundry. They are cast in grey cast iron. As you can see the surface finish is excellent. As always with 'split patterns' there is a bit of 'flash' along the split line, but this is easily cleaned off with a grinder. http://www.dennisfire.co.uk/sil1.jpg http://ww...
by caxton3d
Thu Sep 14, 2017 7:36 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

The next diversion was some printed patterns so that 2 silencer end caps could be cast. The end cap looked like this; http://www.dennisfire.co.uk/te1.JPG http://www.dennisfire.co.uk/te2.JPG You will see that all the dimensions are fractional imperial sizes, befitting something which was designed in ...
by caxton3d
Thu Sep 14, 2017 2:47 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

There has been a delay in printing the core boxes, as there has been diversions along the way. Here is a printed pattern for a throttle/ignition quadrant which is located around the steering wheel; http://www.dennisfire.co.uk/printquad1.jpg http://www.dennisfire.co.uk/printquad2.jpg The print has be...
by caxton3d
Wed Jul 05, 2017 8:50 pm
Forum: Printing Settings
Topic: Optimum settings for support?
Replies: 2
Views: 791

Optimum settings for support?

Whenever I have used supports the surface finish of the area of the model which has been supported, has always been very poor. Admittedly I have been using the same extruder as I have for the actual print (using PLA). Can anyone suggest what I can do to achieve clean supported areas?
by caxton3d
Thu Feb 16, 2017 4:43 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

Jason, I am confused now. Why is IdeaMaker therefore telling me that the model is outside the printable area? http://www.clavis.co.uk/ar44.JPG This is the size that I am trying to print. I have selected a raft 10mm larger all round the model, so my maximum width is 300mm. Should I be able to print t...
by caxton3d
Thu Feb 16, 2017 12:21 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

It s now time to print the core box so that the sand core can be molded. http://www.clavis.co.uk/ar40.JPG This will produce one half of the core. A mirror will be required to produce the other half. The two half sand cores are then glued together with core glue to form the full core. This is the sha...
by caxton3d
Thu Feb 09, 2017 9:33 pm
Forum: Others
Topic: Honeycomb support - poor surface quality
Replies: 7
Views: 2025

Re: Honeycomb support - poor surface quality

In the support section of Ideamaker there is also the 'sparse' support option. I have tried this option and cannot really see any difference. Can anybody show any examples which illustrate this feature clearly?

Thanks.
by caxton3d
Thu Feb 09, 2017 9:28 pm
Forum: User's Gallery
Topic: Patterns for Aluminium Sand Casting
Replies: 56
Views: 10417

Re: Patterns for Aluminium Sand Casting

Walshlg, this is a good idea. I have made a test print where the model had a support column just stopping short of the overhang that I needed to support. I then used the automatic ribbon support feature, so that the support was only 10mm long and did not have issues of flexing due to it's length.
by caxton3d
Sun Feb 05, 2017 2:02 pm
Forum: Others
Topic: Honeycomb support - poor surface quality
Replies: 7
Views: 2025

Honeycomb support - poor surface quality

My thread in the gallery section is detailing the printing of a large tall part to be used as a pattern for aluminium casting. As it was just under 24 inches tall I have had to use the honeycomb type support as the normal thin ribbon support did not have enough stability for this height. However whe...

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