Help with 3D modelling for printing

[David Vandenberg]

Hi guys,

Can anyone here help me with modelling a part for 3D printing?

I have a physical part that I need reproduced with some minor changes.

It’s a fascia plate to go into the dashboard of my car.

I already had a go at modifying the part myself with body filler, but it didn’t go so well. Having a 3D model will be better as I can replicate it and also share it with the community to help others.

I’ve previously done some tutorials on Maker’s Muse for Fusion 360, but I’ve already forgotten 90% of what I learned.

I’m willing to pay, and I can send / deliver the physical part and provide callipers to help replicate it. (I'm in Sydney)

I’ve included some pictures of the existing part so you can get an idea of what it is. (actually... it's not letting me upload right now)

It’s pretty simple and approx 215mm x 128mm x 25mm.

The modifications I require are:

• extending the face to cover the entire opening (currently there's a large cutout)
• adding 2 extra clips on the sides
• adding some recess/score lines on the inside of the face to make it easy to cut out a couple of rectangle holes in the face where required.

Of course, I’m willing to pay someone to create the model for me.

Thanks!

[Clifford Heath]

Where are the pictures?

[David Lyon]

Here's the traditional technique: https://www.youtube.com/watch?v=sSjfKLH9P20

They're just using foam board using 2D shapes and fitting them together, which is lightweight and easy to work with. Then they are covering it in Leather which is quite nice.

When I did my part, because the curves were so complex, I just used Spray-Foam over plastic-sheet and then cut, smoothed and painted to finish. I was happy with the end result and it saw active service for many months.

I do know some professional CAD modellers. They charge $2000 per week in their day jobs ($400 per day) so I think the modelling cost might add up.

It might a good idea for a startup, I know stacks of models of cars where they want tablet mounts and so forth.

Even on Commodores and Falcons, these mounts can go for $500 or so and a lot of what is sold is just rubbish.

Warning on 3D printed car parts though, use ABS and not PLA. It melts in the sun - haha.

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[David Vandenberg]

Thanks David,

I hadn't considered the heat issue of PLA. I guess I'll print in Nylon or PETG or something - researching what is the best for this application.

I've found someone really good to help me with the modelling. He's already mostly done and I only met him yesterday.

Treatstock seems to have a bunch of good local printers that will print in various materials quite affordably. Printing what I need in ASA or PETG with 50% infill works out to be about $30. 

I might do some test prints with PLA at Jaycar before I do the final print.

I do want to 3D print it rather than use another method. I did have a bash at using body filler, but I stuffed it up. A benefit of doing it in 3D is that I can share it amongst the car community and others can benefit from it without needing to have any extra tools or making skills.

Also, if I need to modify it or adapt to another application I can easily modify and re-print.

David Vandenberg Founder The Lab m: 0416163264 w: thelab.com.au  e: da...@thelab.com.au

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From: ozb...@googlegroups.com <ozb...@googlegroups.com> on behalf of David Lyon <david.lyon...@gmail.com>
Sent: Tuesday, 17 November 2020 5:44 PM
To: ozb...@googlegroups.com <ozb...@googlegroups.com>
Subject: Re: [ozberry] Help with 3D modelling for printing

 

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[David Vandenberg]

Sorry Clifford, I completely missed your message.

Google isn't letting me post any images for some reason. I even tried resizing to less than 800x600 jpg and still giving me errors. I don't need help with the modelling anymore though. Found someone already who is really good. 

Images would still be nice for reference, so I may try attaching via email client rather than Google Groups interface.

[David Vandenberg]

Attempting to attach images via email....

David Vandenberg Founder The Lab m: 0416163264 w: thelab.com.au  e: da...@thelab.com.au

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From: ozb...@googlegroups.com <ozb...@googlegroups.com> on behalf of David Vandenberg <da...@thelab.com.au>
Sent: Wednesday, 18 November 2020 1:38 PM
To: OzBerry <ozb...@googlegroups.com>

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[David Vandenberg]

Already have some progress. The basic shape of the model is done.

Just need to add the clips, remove some of the material and produce several variations with different cutout locations.

The hardest part is done - modelling the face, which is curved along 2 planes and needs to mate perfectly with the car.

The remaining challenge is how to model the clips, which need to flex while being strong enough to not snap along the layers. As I'll be sharing this with the car community, I want it to be reasonably idiot-proof, and can't ensure that it's printed in a certain orientation.

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From: ozb...@googlegroups.com <ozb...@googlegroups.com> on behalf of David Vandenberg <da...@thelab.com.au>

Sent: Wednesday, 18 November 2020 1:39 PM

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[David Lyon]

It's for your friends in the Lamborghini community?

https://www.youtube.com/watch?v=GlP6C1z5abM

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[David Vandenberg]

Lol. I don’t own a Lamborghini 😂

It’s for an old Alfa Romeo to allow people to install modern CarPlay / Android Auto touchscreen systems. There are commercial dash trim kits available for this car but they are really poorly designed. They look awful and are structurally unsound, with the system installed in a cage attached to the fascia - bearing a heavy load on clips attached to the trim.

My solution was involves a separate bracket and fascia. The bracket solidly secures the system to the car and the fascia merely clips on to the dash in front of it for a clean install.

I’m designing a few variations for different system installs and also a full fascia that allows for custom cutouts for the modern floating screens, which only require a small cutout for the hinge, or have the screen completely decoupled from the main head unit.

I’m not doing this commercially. I just need a better solution for myself and will be publishing the designs for free on thingiverse and car forums so everyone can benefit.

David Vandenberg

Founder

The Lab

m: 0416163264

w: thelab.com.au

e: da...@thelab.com.au

From: ozb...@googlegroups.com <ozb...@googlegroups.com> on behalf of David Lyon <david.lyon...@gmail.com>

Sent: Thursday, November 19, 2020 3:25:37 PM

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[Clifford Heath]

David, which old Alfa?

I have a 1969 GTV 1750 with LSD and twinspark conversion.

Clifford Heath

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