Today reader Ian McKee, whose blog handle is 45Bravo, begins telling us about the additive manufacturing. To learn what that is you will have to read his report.
If you’d like to write a guest post for this blog, please email me at blogger@pyramydair.com.
Take it away, Ian
Additive manufacturing: Part One
by Ian McKee
This report covers:
- Additive manufacturing
- I like 3D printing
- Limitations
- Common materials
- ABS plastic
- BB’s turn
Additive manufacturing
Additive manufacturing is a term that describes 3D printing. It means making an object by adding layer upon layer until you have your desired part. That would be the opposite of subtractive manufacturing. where you are removing material from a solid block like all machining operations including CNC (Computer Numeric Control) operations do.
Marble statues of the Renaissance period were made by subtractive manufacturing. (Just chip away everything that doesn’t look like the guy named David in front of you.)
I like 3D printing
I am a big supporter of 3D printing and design. I love being able to make parts for obsolete airguns, to let them be enjoyed for future generations. But my machinery is limited in the quality and durability of the things it can produce.
Limitations
I do understand the limitations of home additive manufacturing, specifically where you are heating plastic to make layer upon layer to create an object (think of a hot glue gun being controlled by a computer).
Common materials
Most hobbyists use PLA (Poly Lactic Acid) which is derived from corn starch, or PETG (polyethylene terephthalate glycol) for 3D printing. That material is inexpensive, recyclable, and produces no harmful vapors unlike other materials.
ABS plastic
Some people print in ABS plastic (acrylonitrile butadiene styrene) which is very durable and highly temperature resistant, but the fumes ABS gives off when heated are toxic. ABS is also prone to warping if there are any changes in the ambient air temp during the printing process.
ABS is much better suited to injection molding than 3D printing, as the hot material is injected into the mold and then quickly cooled. Tom has discussed the cost of manufacturing airguns and accessories in the past. Part of that was the cost of making the molds used in injection molding plastic, unless you are turning out thousands of a single part, the cost can be very expensive.
Tom will be reviewing the Umarex Notos and the parts some owners use to enhance an already great carbine. The parts he will be testing are made using several different forms of additive manufacturing by Terry Harmon with Buck-rail.
I will also be covering another manufacturer, Black Arts Designs, who is already selling many of his designs here on Pyramyd AIR. He makes parts that fit Air Venturi airguns, RAW, AEA, FX, Element Optics, and Riton optics — just to name a few.
I am applauding both of these manufacturers because they both started off small, and have grown to be real contenders in the airgun marketplace. And have been pushing the limits of 3D printing into areas that the normal hobbyist just can’t go.
Yes they are competing against each other, but they each have different ideas and backgrounds, and coexist in the market, each following their own path to success.
I will be writing this series because I would like to highlight their unique ways they are elevating the quality of additive manufactured parts for our hobby.
Tom can write about the airgun and the accessories, and I can write about how the parts are made.
It isn’t just cheap, fragile, plastic 3D prints anymore.
Shoot safe, have FUN!
Ian
BB’s turn
This is a great topic because we are seeing more of it in our airguns every day. Through Ian’s writing you should learn a little more about the parts that make up the airguns you enjoy.
I chose the Umarex Notos precharged pneumatic (PCP) air rifle to test because of so many good comments I heard about it. But a strong second reason for my choice is the number of aftermarket parts and accessories that have been made available through 3D printing. As Ian said, Buck-Rail is a major provider of these parts, but they aren’t alone. I have already received a 7-shot rotary magazine and a single-shot loading device from Maple Custom Products, a Canadian manufacturer of 3D parts. I won’t tell you any more about those products until I test them, but when I do I plan to show you they are both 3D printed.
This series will run on its own and the Notos report will run separately. But every time I use something that has been 3D printed I will refer back to this series.
For lower-cost injection molding tooling, look at hardened sand molds. We print the molds at the company I work at, and other companies harden them. Check out ExOne, Catalysis, and AM Toolbox. For lower volume and prototyping, they’re great.
The owner also wants us to get into metal printing, but we’re not there yet.
Tom and Ian,
As I understand it 3D printing is for rapid iteration and low volume production. How does one determine the tipping point where it makes more sense to use traditional production methods?
Siraniko
Siraniko,
I’ll let Ian take that one because I have no idea. But tomorrow you will see a prime example of the good 3D printing can do.
BB
Sorry for the delay in responding, been a long day at work.
That would depend on the individual businessman and how large he wants to become, and how far he wishes to penetrate the market.
Both of the companies mentioned above started small, but have embraced the business and have grown accordingly.
There is a company in Croatia that sells 3D printed airgun accessories, he has 20 printers. He has a website and his business has world wide reach, and his magazines are well received by owners.
But he only prints on demand, as the orders come in. As some customers may want special colors. or other one off things.
He also wants to make sure each item he sells is up to his level of quality.
If you farm your manufacturing out to a contractor, you lose that control of your quality.
To each their own.
A mutual friend put us in contact, and I will soon be testing some of his designs. I knew of him before this, and acquired one of his magazines with a gun I traded for, but we had never formally communicated.
Hopefully, he is ready to buy more printers…
Ian
Ian,
One of the long range shooters at my range 3-D prints lots of stuff for his airgun. He has made lots of “chamber flags” for PCP’s. He made a cup holder for my coffee mug when I drive.
I also have a scope wheel that somebody else made. As more 3-D materials and the printers that can use them become cheaper, you will see more and more one off stuff. Should be an interesting future…
-Y
Yogi,
I have an image in my mind of Jon Luc Picard standing in front of the replicator saying, “Tea — Earl Grey.”
BB
B.B.
Star Trek did NOTHING for me. I am thinking about the metal bridge they made over a canal in Amsterdam or the additive cement buildings going up in the Texas desert.
-Yogi
Tom,
With the current state of the environment that one would definitely be full of microplastics.
Siraniko
Siraniko,
Just as the coal spilled onto rail beds from coal trains, the rubber worn off vehicle tires keeps disappearing along our streets and highways by the good works of various flora and fauna there are similar natural creatures and plants that have been found ganging up on microplastics in the environment.
Unfortunately the Mainstream Media is not interested in reporting what turns out to be wonderful news. There are very wealthy laboratories that want to genetically alter bacterium, which of course will be Patented, for the increase return on investment (ROI) that also want to downplay the good news.
Such is life in our times…all have an agenda that doesn’t include doing the common good any favors.
shootski
Yogi, I have made coasters, business card holders, and many non-gun related designs.
Sight inserts, rear sights, scope mounts and other things for obsolete airguns. And I have even 3D printed airgun projectiles. (upcoming blog about that soon.)
If you can think it, it can be printed.
Is it a permanent solution to a lost or damaged part? Sometimes, it depends on the application.
It may take 20 minutes to print, or it could take 20 hours (or more) depending on the size and complexity of the model, and the filament used.
I print model kits for my grandkids to build.
If i do nothing but make things for the grandkids and family, I am happy with the 3D Printer.
There are literally MILLIONS of free designs online that can be downloaded and printed.
There is a site called THANGS.com that you can browse online.
That site brings together the files from many different sites into one place.
Ian
Ian,
I imagine a future where you upload your plans to your local hardware store/library/community center and they can make whatever you need. Plastic, metals, cement, electronics, wood, any material that you can think of…
-Y
Buckrail is already using a laser system, for 3D printing.
a layer of plastic powder is laid down, and a laser bonds it to the previous layer, over and over again.
I have seen that also with aluminum, it makes for a very good clean and strong print. Much better than the traditional method.
Ian
Ian,
JD Customs did something similar to print my scope wheel. When we get to 3-D printing of titanium I will be impressed.
-Y
Sorry, I think this is how Formula 1 teams make their suspension parts.
-Y
its already happening.
https://www.xometry.com/capabilities/3d-printing-service/direct-metal-laser-sintering/?utm_term=titanium%203d%20printing&utm_campaign=PB:G%7CNT:SN%7CAN:Manufacturing%7CCN:3D_Printing_Exact_Non_Business&utm_source=adwords&utm_medium=ppc&hsa_acc=3789459769&hsa_cam=21656675037&hsa_grp=165615285726&hsa_ad=712074465484&hsa_src=g&hsa_tgt=kwd-317124568497&hsa_kw=titanium%203d%20printing&hsa_mt=e&hsa_net=adwords&hsa_ver=3&gad_source=1&gclid=Cj0KCQjwsJO4BhDoARIsADDv4vATH1x6VEYbscMQQNuP18rJBdfLQf4_eHn09uT0m4kqZqR2xvWhSe0aAu2rEALw_wcB
MAZAK made (still makes?) a horizontal lathe/machining center that includes additive, as well. The powdered metal is sprayed & laser sintered for build up on a part and then machined to final size.
Titanium was one material that they mentioned, as was Inconel. The future is very close at hand!
Bill
High-end firearm suppressors are made by 3d printing titanium. Also Inconel, also used in 3d printed rocket motors. (If we had more space at work, the owner of the company would have leased some footage to a company that 3d prints rocket motors.)
Thanks for this series of reports. I have already acquired quite a few of the BuckRail products and have been very pleased with the products and the people responsible. I have said it here before, ingenuity always fascinates me. A lot of ingenuity goes into the concepts and the execution of those concepts. For example take a look at the Side View device available at Black Arts Designs. A simple, elegant, and effective solution to a problem with the design of some Airguns. If they made one for the Notos, I would definitely consider purchasing one.
Ian,
Thanks. I have always wanted to know more on this subject. I have seen some examples at work of this method and have actually went to VPI for a tour of their 3D printing facilities. Really, it was quite impressive. It will be most interesting to see where it is now.
Ian
Lacking knowledge about this subject this report has already been a learning for me. Bring it on Ian! Looking forward to much more is an understatement.
Deck
Always good to learn something new, even outside one’s own area of non-expertise; also good to support the smaller manufacturers who make useful products like these airgun accessories mentioned here and who care a little bit more about making them right than the bean counters at BFCI – Big Fat Conglomo Industries.
Thanks Ian!
I’ve been watching 3d printing for over a decade and it’s mostly been a technician’s hobby. I’m happy to see that reasonably priced, plug&play units for the casual user are now available.
Unfortunately, my wife is extremely sensitive to chemicals and fumes and I can’t see having a 3d printer in the house. 🙁
There’s a lot to be said for the additive process of making things. I just wanted to mention that a lot has been happening with subtractive machines for the home user. Similarly priced to 3d printers there’s a huge variety of very capable laser and routing machines available. I have a Longmill MK2 (
https://sienci.com/product/longmill-mk2-5-2/ ) that’s been useful for many of my projects.
Both the additive and subtractive machines require software to create the files that drive them. Fortunately, open source freeware like FreeCAD (3d modeling) and InkScape (vector graphics design) are available for download.
Interesting times!
Cheers!
Hank, I have friends that do the subtractive side of the hobby. I personally haven’t jumped into that area as yet.
The Bambu line of printers stood the 3D printing world on its ear..
Until then, you were always tinkering with the printer.
The newer ones are a lot like a printing appliance. You find a file on your phone, or computer, choose your printer, if it is loaded with filament, you tell it to print, even if you are in another city!
Ian