Car Grille

3D Printed Custom Made Car Grille For Form Fitting

Other than printing models such as Ford Model T, this round we printed a custom made car grille. Depending on what materials the vendor use i.e. metal or ABS , car grille would undergo CNC machining or injection molding process for the finished product. In this round, we tried to simulate the similar environment by 3D printing it.

Technology: FDM
Printer:  Fortus Production Series
Materials: ABS M30 – Ivory
Build Time: 41 hours 25 minutes

Screenshots prior printing:

Outcome:

Implications:

  • To develop a customised prototype such as this CNC machining would take up to approx. 3 weeks, and injection molding (including mold process up tp I.M) will take months. This is 3D printed in 2 days at an accessible cost.
  • Conventional method will face difficulty in producing such complex shape hence taking longer time, that is where 3D printer comes in.
  • Technology wise, Polyjet’s Digital ABS (theoretically) is also capable of simulating such form fitting test. However FDM was the preferred option as it uses engineering grade thermoplastic materials, which in this case is ABS M30. Other than design validation, this will provide a realistic analysis to car manufacturers in terms of tensile strength and elongation test which will aid in their mass production process.
  • Also, FDM material is also suitable material for outdoor testing given at extreme condition such as mud, sleet, rain, snow, humid and etc.
  • The 3D printed car grille can also undergo UV coating / chrome plated for better finishing & further testing purposes.

 

3D Printed Ford Model T

The Ford Model T was the most popular auto mobile back in 1920s as it was the first car made affordable to the masses. Without doubt, we at RMD are also huge fan of this vintage model and we decided to print this as one of our lucky draw gift for our past DDM event.

Below is some information on file source & technology we used:
File Source: Thingiverse
Technology: Polyjet
Printer:  Objet Design Series
Materials: VeroBlack, VeroWhite, VeroClear
Build Time: 3 hours and 41 minutes

Screenshots prior printing:

Outcome (after assembly):

Ford Model T Car Model

3D Printed Ford Model T Car Model

Implications:

  • We decided to use Polyjet due to its precision and performance, the model parts came out in a brilliant form. All parts were printed precisely and we have no problems in fitting them in. By the way, Connex3 can go up to 16micron (0.016mm) per layer!
  • Another reason for Polyjet is due to the possibility of printing multi-materials multi-colors in a go. This means you can get multi-color composite materials (refer to the grey parts, it’s a mix of black and white). Depending on application, you can also have composite materials withdifferent shore levels by mixing rubber-like to translucent material.
  • Does that mean FDM is inferior to Polyjet? Not really. It all depends on what kind of applications that you’re looking at. Say if we were to do functional prototypes that requires high endurance/tensile strength, FDM is the way to go.