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Driver door assembled

by Ivan Sentch 6. April 2013 09:21

Driver door assembled, that's 5.5m2 done now of 16 and the printer's still going well



Passenger door assembled

by Ivan Sentch 15. March 2013 19:48

Passenger door assembled, driver door mostly printed (about another 3x days left). I'm falling a bit behind in assembling vs printing but that's ok



Passenger door printed

by Ivan Sentch 7. March 2013 07:24

Passenger door printed and partially assembled, Driver door is now printing. I'm also trying a new way of printing, some people have tried printing on a pane of glass coated with hairspray, I tried this but the prints wouldn't stick to the bed, I was about to go back to the old way when I tired using the kapton tape on top of the glass (instead of on the aluminium bed) and it seems to stick better to the glass than the aluminium and it seems to last about 3x longer so I don't need to change it as often and I don't get any prints that have pealed the kapton tape off the bed.


Body | 3D Printing

Bonnet Assembled

by Ivan Sentch 14. February 2013 07:08

All done, this took a while (you might notice I ran out of black). Now on to the passenger door



Creating the framework

by Ivan Sentch 9. February 2013 13:50

The 3D design tool I'm using is Autodesk 3DS Max 2011, this has the standard feature of creating cross sections of your object which is how I make the framework the panels sit on.

I first give the object depth so the printed sections will sit flush on the framework, then create the sections, no real science with this just as many as I feel are needed to keep it true but i do offset their positions so they do not line up with where my extruded edges will be (otherwise I'll need to manually take more off the outline in order for the sections to sit flush)

I then export the shapes to another program (I can't seem to find a print to scale option in 3DS max so I use another very simple CAD program called AllyCad) and print them out to scale (normal printer that is). With these I transfer the shape to MDF and cut it out (you could use a 2 axis CNC machine for this but a jigsaw works just fine)

These are then glued / screwed together using square blocks to keep it square.

There's a good youtube video about this here:


Body | Design