Big Builds, Small Build Envelope...How do you do it?

Alex3DHubs · 2015-03-11T19:03:05.000Z

I think what you are looking for are ‘keys’. Essentially, they allow you to easily reconnect parts after a plane cut or something similar. Bold Machines has a pretty solid tutorial for printing their movie characters, although they dont go over much detail for the software process. Hot glue is apparantly useful also

DaveDelay · 2015-03-11T19:45:32.000Z

With ABS part I use “same stuff” or Ambroid “ProWeld” to fuse surfaces together. Keying if necessary. I got that tip from a tour of Stratasys back in the mid 90’s

Gary · 2015-03-11T20:05:29.000Z

The software 3D-COAT has a feature that will split an .stl, and automatically add in alignment pegs and holes.

Pot8oSH3D · 2015-03-11T23:32:12.000Z

Yup. That’s more-or-less the process I use. I wet the mating surfaces with Acetone before I stick em together with ABS/Acetone slurry though, just to soften the surface and ensure the dry surface doesn’t absorb the Acetone out of the slurry to quickly. A good sanding afterwards finishes the job. Spot the joint…

Cheers!

AndyL

Pot8oSh3D

IMG_0594.jpg2448×3264 2.44 MB

Cinter · 2015-03-12T00:07:49.000Z

Fantastic responses, keep them coming!! ‘Keys’ seem like a great idea particularly for alignment. Some of the techniques still sound a bit messy and dare I say it not very user friendly. Is anyone out there trying chemical free solutions?

Cinter · 2015-03-12T00:10:27.000Z

@Gary we will definitely be trying out this software, thank you and it’s free (seems too good to be true).

Cinter · 2015-03-12T00:17:30.000Z

@ST3P_GLASGOW This project is great! A really useful and helpful post too. Are you able to tack the parts together before fully attaching and would this be of benefit to the process if you don’t?

LA_3D_Print · 2015-03-12T00:23:45.000Z

I have built around 6 large scale models that have been larger than my build plate. One project had 212 parts!

Many different ways to do this.
Pegs are awesome
Allow holes to run through center of parts to insert metal rod or PVC pipe. Make it like a shish kebab

Weld edges together with soldering iron
Friction welding with dremil and old filament.

Bondo
or xtc 3d

Sarah_id · 2015-03-12T08:48:22.000Z

This is a great post, thank you.

We had a similar experience but with another 3D printer. The task was to print a full scale large UAV (150cm*200cm) using a printer with a small build envelope.

We sliced it up using CATIA, then glued the pieces with superglue and a gap filler, then sanded it and painted it. It turned out pretty well.

Picture: https://igcdn-photos-e-a.akamaihd.net/hphotos-ak-xaf1/t51.2885-15/10848447\_1646891178871916\_787689164\_n.jpg

STEP_GLASGOW · 2015-03-12T10:42:54.000Z

we’d definitely be interested in keys, but skeptical about the fit due to shrinkage. If there’s some way of adding keys with consideration for shrinkage, we’d love to find out more about it!

Voltl_Design · 2015-03-12T11:05:19.000Z

I bought the 3D Doodler pen for just this reason, when i have curling at the edge surfaces, I will glue the pieces together and where I have gaps, I will plastic weld the two pieces together to create a smooth surface.

Voltl_Design · 2015-03-12T11:08:45.000Z

Does this software account for FDM printers hole shrinkage because if I have models that need connector? As a way to combat this issue without an automatic solution I will model the part and offset the hole by .0125" to adjust for printer tolerance.

Joerg_4 · 2015-03-12T12:36:07.000Z

“…, thank you and it’s free (seems too good to be true)”

it really is? I just find a limited trial for free, did I miss something?

MetaCAD · 2015-03-17T14:15:19.000Z

IF YOU HAVE AUTODESK INVENTOR, LIKE WE DO. THERE IS AN APP TO DOWNLOAD.

apps.autodesk.com

3D PRINT | Plugin, Add-on, Extension for Inventor | Autodesk App Store

Autodesk App Store is a marketplace and a web service provided by Autodesk that makes it easy to find and acquire third-party plugins, other companion applications, content and learning materials for Inventor. You can find the most up to date...

OR

apps.autodesk.com

Autodesk App Store

CHEERS

BARRY

METACAD ENGINEERING SOLUTIONS LTD

www.metacad.co.uk

Cinter · 2015-03-17T14:22:11.000Z

Great to see so many fantastic pieces of software that are making this easier. @MetaCAD do you have any experience of how they cope with thin-walled large builds?

Cinter · 2015-03-17T14:24:16.000Z

You are right, fooled by the 30day free-trial

MetaCAD · 2015-03-17T14:34:48.000Z

I WILL LOOK /SCOPE AND REPLY LATER

DOWNLOADED IT AND USED IT ON ONE JOB SO FAR.

Dwayne · 2015-03-17T17:53:54.000Z

Solvent welding is the best solution I have found. Despite what community trends may lead you to believe, acetone is not ideal for dissolving ABS. MEK (butanone) works far better and is commonly used when assembling plastic model kits. If you don’t have a perfect fit between pieces solvent welding will not produce a strong void-free seam, you need to dissolve some ABS in the solvent to create a glue that can fill the gap. I have also experimented with friction welding (ABS filament in a handheld rotary tool) but I don’t think it’s ideal for most parts as the weld is only on the surface. It has applications, but is more limited than solvent welding.

Joseph_1 · 2015-03-17T18:41:19.000Z

Is there anything 3D Coat can’t do?

stephan_5 · 2015-03-26T14:29:27.000Z

Or you modify your printer a bit…

https://ultimaker.com/en/stories/view/97-printing-out-of-the-box