3D printer job?

I need 4 new aka bar endcaps for my Hobie AI and they are $10 each, plus about $10 shipping plus tax, which seems pretty crazy, even by Hobie standards. So, I'm wondering if this looks like something that is suitable for 3D printing and, if so, whether there are any 3D printer people in NCKA-land who might be interested in giving it a try. I'd be glad to pay--even if it costs as much as Hobie charges, I'd rather pay somebody here than Hobie.

The overall height is 2.875" and the maximum diameter is 1.625", and it's hollow. The plastic appears to be about 3/32" thick. I'm not sure what type of plastic it is, but it's very rigid. The thickness of the material is not critical, just the outer dimensions, as it needs to fit inside of an aluminum tube. I can provide detailed drawings.

If you can provide me an Autocad drawing of the part I'll 3D print them for you for free.

Actually, that looks pretty easy to draw up in Solidworks or any other Autocad program.
Send me the dimensions and I'll see if I can have one of my homies model it and I'll print it.

Hi NW, started a design in TinkerCad - free web based, surprisingly useful

https://www.tinkercad.com/things/jSx70BGO9Pt-mighty-curcan-jaban/edit?sharecode=WKv0HT3UZaV6UahQUs3apDlSvlzGb1fPtsvP0GOQ510

that link allows you to edit it

I started with a cylinder, 1.625 in diameter
and an larger oval - that i guessed at the sizes

I (or others) can generate a file to print from this once we decide on it.

Hi NW, started a design in TinkerCad - free web based, surprisingly useful

https://www.tinkercad.com/things/jSx70BGO9Pt-mighty-curcan-jaban/edit?sharecode=WKv0HT3UZaV6UahQUs3apDlSvlzGb1fPtsvP0GOQ510

that link allows you to edit it

I started with a cylinder, 1.625 in diameter
and an larger oval - that i guessed at the sizes

I (or others) can generate a file to print from this once we decide on it.

Thanks!

I probably won’t have time to look at it today but will soon…

If I have it in my hands, I could help you model it in Fusion 360. The measurement needs to be somewhat precise for that part to be able to plug in the aka and stay put. I don't think PLA would be sturdy enough for this part. I think the original part is some sort of nylon plastic material. Doesn't feel like ABS.

Dustin, what materials do you have available?

To be honest, $10 for this part ain't so bad. If I needed 4, I would just order them from the dealership and save the shipping. The time and material to make four of these is definitely more than $40.

Btw, how do you get so much wear on this part? It's just something you plug into the AMA. Mine don't get any wear at all.

If I have it in my hands, I could help you model it in Fusion 360. The measurement needs to be somewhat precise for that part to be able to plug in the aka and stay put. I don't think PLA would be sturdy enough for this part. I think the original part is some sort of nylon plastic material. Doesn't feel like ABS.

Dustin, what materials do you have available?

To be honest, $10 for this part ain't so bad. If I needed 4, I would just order them from the dealership and save the shipping. The time and material to make four of these is definitely more than $40.

Btw, how do you get so much wear on this part? It's just something you plug into the AMA. Mine don't get any wear at all.

I'm building a second AI from (mostly) second-hand parts. When I got the (well-used) aka bars, only 2 of them had end caps, and I removed them (and everything else attached to the bars) so I could strip and refinish the aluminum. The 2 end caps were a bit chewed up, and they'd been gooped into place, so it was a challenge to get them out.

I don't think the fit is super-duper-critical--at least if it's marginally too small, some goop (or similar would hold them securely in place.

I also removed the collars that hold the amas in place, and those all got damaged in the process. They're less than $5 each, but I made some out of starboard plastic that I think are better than the original.

You're probably right that $10 for an end cap is not too bad, but I've been jonesing for a 3D printer, and if this can work, I'd probably spring for one, as I can imagine all kinds of AI do-dads I'd like to make...
 

I was going to print it on a Formlabs Form3 with their Tough material.

I was going to print it on a Formlabs Form3 with their Tough material.

I have no experience on resin printers. I do know the regular resin-printed parts are brittle. However, new materials come out all the time. Perhaps these tougher materials have practical uses. The surface details of these resin printers are very impressive for sure.

... but I've been jonesing for a 3D printer, and if this can work, I'd probably spring for one, as I can imagine all kinds of AI do-dads I'd like to make...

That plug would be a perfect first project if you were getting a 3D printer. You seem like someone who would benefit from having a 3D printer. I analyzed and believe that the replacement plug would work well if you use a DPU material. If you send me a spare part, I'd be happy to model it and possibly print it for you.

Regarding software, the TinkerCad is a quick and dirty tool that can produce parts that aren't very complex. However, the most annoying part of TinkerCad is the resolution limitation. The models they produce are very segmented. You will not be able to produce smooth curves.

Fusion 360 is free for non-commercial use. For Educator/Student, you use to get a 3-year free license (not sure if things changed) that can be renewed if you are still in school. For non-commercial personal use, you get 1-year free license that can be renewed every year. Fusion 360 is not CAD, but it is very capable and a lot easier to use than typical CAD software. You will be able to model anything in Fusion 360. It does require a small learning curve, but it is not rocket science.

Good luck with your build.

ernest

... but I've been jonesing for a 3D printer, and if this can work, I'd probably spring for one, as I can imagine all kinds of AI do-dads I'd like to make...

That plug would be a perfect first project if you were getting a 3D printer. You seem like someone who would benefit from having a 3D printer. I analyzed and believe that the replacement plug would work well if you use a DPU material. If you send me a spare part, I'd be happy to model it and possibly print it for you.

Regarding software, the TinkerCad is a quick and dirty tool that can produce parts that aren't very complex. However, the most annoying part of TinkerCad is the resolution limitation. The models they produce are very segmented. You will not be able to produce smooth curves.

Fusion 360 is free for non-commercial use. For Educator/Student, you use to get a 3-year free license (not sure if things changed) that can be renewed if you are still in school. For non-commercial personal use, you get 1-year free license that can be renewed every year. Fusion 360 is not CAD, but it is very capable and a lot easier to use than typical CAD software. You will be able to model anything in Fusion 360. It does require a small learning curve, but it is not rocket science.

Good luck with your build.

ernest

Education/ student licenses are still 3 year. Hobbyist/enthusiast is the way to go though

FDM method of printing asa would be great. asa is fantastic in uv and also easier to print than abs, while maintaining a close list of properties. I use autodesk inventor and find it to be extremely similar to Solidworks minus the fillet and lofting logic.   Fusion360 is pretty nice and free noncommercial use.

Hi NW, started a design in TinkerCad - free web based, surprisingly useful

https://www.tinkercad.com/things/jSx70BGO9Pt-mighty-curcan-jaban/edit?sharecode=WKv0HT3UZaV6UahQUs3apDlSvlzGb1fPtsvP0GOQ510

that link allows you to edit it

I started with a cylinder, 1.625 in diameter
and an larger oval - that i guessed at the sizes

I (or others) can generate a file to print from this once we decide on it.

not sure what happened, but someone destroyed the design - could have been an accident.  NWM, let me know if you want me to re-create, and I can share with you on PM. 

Thanks,
Brian.

Hi NW, started a design in TinkerCad - free web based, surprisingly useful

https://www.tinkercad.com/things/jSx70BGO9Pt-mighty-curcan-jaban/edit?sharecode=WKv0HT3UZaV6UahQUs3apDlSvlzGb1fPtsvP0GOQ510

that link allows you to edit it

I started with a cylinder, 1.625 in diameter
and an larger oval - that i guessed at the sizes

I (or others) can generate a file to print from this once we decide on it.

not sure what happened, but someone destroyed the design - could have been an accident.  NWM, let me know if you want me to re-create, and I can share with you on PM. 

Thanks,
Brian.

That was probably me. I tried to edit it, but couldn't see how to get the right shape with the limited options. The part that goes inside the aluminum aka bar is not elliptical, but a cylinder with 2 of the sides flattened--the intersection of a circle and a rectangle would give the desired shape.

I've downloaded a free version of Autodesk Fusion 360 and have played around with that a little too. But, it seems to be pretty complex, so I'll have to do thru a couple of tutorials to have any chance of doing something with that...

Hi NW, started a design in TinkerCad - free web based, surprisingly useful

https://www.tinkercad.com/things/jSx70BGO9Pt-mighty-curcan-jaban/edit?sharecode=WKv0HT3UZaV6UahQUs3apDlSvlzGb1fPtsvP0GOQ510

that link allows you to edit it

I started with a cylinder, 1.625 in diameter
and an larger oval - that i guessed at the sizes

I (or others) can generate a file to print from this once we decide on it.

not sure what happened, but someone destroyed the design - could have been an accident.  NWM, let me know if you want me to re-create, and I can share with you on PM. 

Thanks,
Brian.

That was probably me. I tried to edit it, but couldn't see how to get the right shape with the limited options. The part that goes inside the aluminum aka bar is not elliptical, but a cylinder with 2 of the sides flattened--the intersection of a circle and a rectangle would give the desired shape.

I've downloaded a free version of Autodesk Fusion 360 and have played around with that a little too. But, it seems to be pretty complex, so I'll have to do thru a couple of tutorials to have any chance of doing something with that...

if you want to jump on a zoom i can model the part for you

  Interesting thread.  I've been curious about how 3d printers work, but never even tried to You Tube them. 
  But while reading, an idea, not necessarily a good idea, occurred to me: Instead of building up, why not whittle down?   Couldn't you find a block of some kind of semi-flexible material and cut away everything that doesn't look like what you want to end up with?