Printed Challenger Pilot

[SG3950]

Ok, next step, you need to print an engine frame with integral cylinders!

Give it time, as costs come down and you will see this. Between the time and cost to make complex, cored patterns and finding a foundry willing to do it now days... Plus you could print the liners in the cylinders and only have to perform a finish machine step. I have had no problem boring holes in this stuff with carbide boring bars.

Here is a picture of the trunions that I made out of the same stuff. I oversized the OD by .050 and used a boring bar to finish cut. 300 RPM, .001 per rev. Cut dry with brazed carbide insert bar that was about 1" long.

[kcameron]

Ok, so what was the basic dimensions of this thing, how heavy, what cost?? I happen to be taking a couple of courses at a local college and the prof is interested. I am comparing it with the pilot work that Pamela did. The result is some of the tradeoffs of time vs money.

[Pipescs]

Having used Shapeways for a few years now for patterns I can only brag on their service.

On the subject of structural/pressure rated parts printed directly from the metal I have no experience. But they due post the following disclaimer:

Disclaimer:
Please note that the 3D printed products are intended for decorative purposes. They are not suited to be used as toys or to be given to underage children. The products should not come into contact with electricity and be kept away from heat. Our materials, except for Porcelain, are not food safe.

This particular link at the bottom talks about the fusion of the steel powder with bronze to strengthen it.

https://www.shapeways.com/materials/steel?li=nav

In emails with the service department they make it quite clear that the process may still be somewhat porous and not meant for structural applications.