CAD models and 3D printing Retrofit parts

[JimAvant]

Hi everyone so i had to change the wipers in my B6 and i found out i had the old style arms but being me i decided i would rather have the new aero wipers... so i bought some.... hmmm no fit!

So only thing to do is make them fit! Right? Just so happens my career enables me to 3D print and create cad designs.. after modelling the arm end and new wiper profile i managed to create a nice enough piece that would enable me to get these nicer looking wipers connected and below is a pic for you all to check out.. and of course i will pass the cad file and/or 3D print file to anyone who may be interested.

Any more of you guys have CAD designed retro fit parts like this you want to share get some images up it would be interesting if we could put a list together for users.

This works in conjunction with a small bolt/nut through the visible hole and the holes already on your wiper arm, it is very easy to install the wiper as it slides in and will not release unless you remove your bolt.


Wiper aero fit link Clicky

[B6A4Dave]

Wait...you mean to tell me you can 3D print a little piece that uses the Shitty old arm and allows use to use Aero blades!!!


OMFG SIGN ME UP!!!!!!!!!

[JimAvant]

Indeed sir! I have been running them on my avant for about 3 months with no issues so i guess its time to confidently share. Anyone interested i can email them my files. Maybe someone can host it and share that way? totally editable for you lot btw if you wish to customize the audi symbol to something else.

[kwimberly]

I bought an armrest latch from Shapeways rather than having to buy a whole new lid. Works pretty well.

http://www.shapeways.com/model/87474...-standart.html

[Willënskraft]

Pics for comparison?


Sent from my iPhone using Tapatook

[B6A4Dave]

Yes...very interested to see pics of said device in use...

[jaydeff]

That's awesome! You can just upload the file to mega.co.nz or a similar file hosting website and post a link here.

[blitz2190]

I'm in the process of making a pod vent on my printer I'll share the cad file when I'm done

[JimAvant]

So here are some pics guys of a simpler more brutal version i am using. hence why i added the chamfers and audi rings before i shared. as you can see i need to do some painting...

[ZipMeUpJ]

Wow this is great. And that vent pod would be awesome too!!

What about glovebox hinges??

[JimAvant]

Anything can be designed Zip you just have to get the dimensions, i have some other things in design that folk might like.

[Pr1ce]

Mind blown

[blitz2190]

Yea I could do hinges, o just got my printer back up and running

[DiertyEuroSpec]

Was just about to get some aero arms off a B& but this looks interesting and would deff be in for supporting further B6 line products and features. You have my money...Get a finished piece up and show some pics!! I know sky's the limit with 3D printing, very interesting field

[JimAvant]

The link is in the 1st post there will be no money involved just get the use of a 3D printer with some decent plastic. I am looking at making a mod where i can put my light switch in the small shelf where i put my wallet and use the light switch hole for a boost gauge. Would this be do-able?

[Luxus Panzer]

The link is in the 1st post there will be no money involved just get the use of a 3D printer with some decent plastic. I am looking at making a mod where i can put my light switch in the small shelf where i put my wallet and use the light switch hole for a boost gauge. Would this be do-able?

Can not say I like this idea. Your eyes will have to come WAY off the road to check gauge. Not safe.

Trust me. I had 3 B4s with sport gauges down by the Ashtray... Took eyes right off the road to check them and was not good.

[JimAvant]

saves me drawing that one up then haha. Anyone with ideas can post them up if i have easy enough access to the parts i can CAD them and post links to the print files. Any ideas for improvements also welcome.

[MacFady]

... the small shelf where i put my wallet ...

Said "small shelf" is the factory home to most peoples owners manual.

[a4darkness]

Been looking to get into this myself, well done Jim. You use Solidworks for this or something else?
Very interested to hear about your process as well, if of course you feel comfortable posting about that here.

[fyremanpat]

Maybe you can 3D print me a bigger twin scroll turbo?....

[fR3ZNO]

Maybe you can 3D print me a bigger twin scroll turbo?....

This guy can.

[blownb6]

thanks for drawing, i will get this printed asap. ill post pics when done

[JimAvant]

Been looking to get into this myself, well done Jim. You use Solidworks for this or something else?
Very interested to hear about your process as well, if of course you feel comfortable posting about that here.

I am using Catia for my CAD modelling what do you mean by process? the printer?

[JimAvant]

Said "small shelf" is the factory home to most peoples owners manual.

My owners manual lives in the glovebox..? its the small shelf by your knee possibly Americas A4 have different placement

[diagnosticator]

Of course, this is only applicable to parts suitable for the materials available for use in 3D printers. Just because it can be 3D printed, doesn't necessarily mean the results are suitable for actual use as a machine component.

For example, the part for the wiper blade adapter, is the material UV resistant? Since UV is used to solidify the liquid plastic in the 3D printer, many plastics will degrade and crumble after long term exposure to UV in Sunlight. Carbon Black is the most frequently used UV shielding material for plastics. However, that would prevent the UV sensitive liquid plastic from reacting properly in the printer. The 3D printing process uses a single frequency UV laser, sunlight exposure includes all of the UV frequencies, and will have an effect on the material. A UV blocking surface treatment may be useful, but it would be hard to maintain the coating. Instead of direct application of 3D printed parts, the printed parts are used as a form or mold to cast the part using a material suitable for the application, ether plastic or metal. Otherwise, CAD parts files can be used as input to CNC machine tools to machine parts directly from metal or plastic.

[JimAvant]

Of course, this is only applicable to parts suitable for the materials available for use in 3D printers. Just because it can be 3D printed, doesn't necessarily mean the results are suitable for actual use as a machine component.

For example, the part for the wiper blade adapter, is the material UV resistant? Since UV is used to solidify the liquid plastic in the 3D printer, many plastics will degrade and crumble after long term exposure to UV in Sunlight. Carbon Black is the most frequently used UV shielding material for plastics. However, that would prevent the UV sensitive liquid plastic from reacting properly in the printer. The 3D printing process uses a single frequency UV laser, sunlight exposure includes all of the UV frequencies, and will have an effect on the material. A UV blocking surface treatment may be useful, but it would be hard to maintain the coating.

Understand what you are saying, i have been running my adapters for a few months now but have not painted them yet as i was testing their structure for every day use. I will however plastidip mine soon as i get a chance primarily for looks but now as you have alerted me of the possibly degradation. I believe the material i have used has a heat distortion value of 56 Celcius which i will never see in this country. it also has a very acceptable elongation at break percentage, totally agree folk should consult their printer and find a suitable material if anyone is interested my parts are made of 'Visijet M3 Crystal'

Further to this it would be very useful if a suitable materials table could be drawn up to assist any forum users looking to create new designs and utilize this technology.

[getslideways]

The 3D printing process uses a single frequency UV laser, sunlight exposure includes all of the UV frequencies, and will have an effect on the material.

A valid concern, but not all 3DPrinting is liquid uv-cured resin based. For example many lower end printers use plastic filament, and both create the end product using the same files, (different methods offer different benefits and compromises of course).

Plus, UV exposure can sometimes make the end result even more fun :



So if the part only lasts a year, a few pennies in material every 12 months, plus the satisfaction of knowing you made something yourself may still make creating your own parts feel justifiable.

Happy Printing!

[blitz2190]

Mines a filament fdm, called a prusa i2. Also I have not only used abs and pla, but nylon as well, which is gas proof as a bonus

[ozMatt]

Sorry for the thread bump, but i have a question for you Jim. I've printed a couple of these out to try, but i found the area with the bolt hole is extremely thin and basically breaks off when i remove the part from the printer.

Do you think it could be an issue with my printer resolution? or does it need to be really thin to fit the blade?

Thanks, Matt

[JimAvant]

Hi matt sorry for the late reply I had sold my b6 but now I have bought another I'm back on here for my fix of fixes... Yes it may be the material you are using or the support material. You could try to thicken up that area in cad, I will try also when I can get a minute in work.

[ozMatt]

Hi matt sorry for the late reply I had sold my b6 but now I have bought another I'm back on here for my fix of fixes... Yes it may be the material you are using or the support material. You could try to thicken up that area in cad, I will try also when I can get a minute in work.

Sounds great, thanks mate

[JimAvant]

Try this matt its been beefed up a bit, have a look on an stl viewer and see if you think it will print https://drive.google.com/open?id=0B-...UVzdEdZSWxaclk

[Evan1028]

Anyone ever actually 3D print an adapter clip to mount normal beam style blades to the stock B6 wiper arms?

[fR3ZNO]

Anyone ever actually 3D print an adapter clip to mount normal beam style blades to the stock B6 wiper arms?

I printed some prototypes just for proof of concept and fitment. I never ended up using them on my own car, though. I was concerned about durability. A carbon fiber Nylon might be suitable. I was considering getting some aluminum ones made through Proto labs or something.

[Kevin C]

I printed some prototypes just for proof of concept and fitment. I never ended up using them on my own car, though. I was concerned about durability. A carbon fiber Nylon might be suitable. I was considering getting some aluminum ones made through Proto labs or something.

My understanding is the cost of the aluminum powder is crazy high. We are getting a 3D printer at work on consignment, crazy expensive. I have offered to provide sample models to test it with. So far no takers. I have seen it used with good results on projects I have been on but too expensive for my own stuff. I have had good results with 3D printed nylon (MJF).

[fR3ZNO]

My understanding is the cost of the aluminum powder is crazy high. We are getting a 3D printer at work on consignment, crazy expensive. I have offered to provide sample models to test it with. So far no takers. I have seen it used with good results on projects I have been on but too expensive for my own stuff. I have had good results with 3D printed nylon (MJF).

I was referring to CNC’d aluminum from Proto labs. Not sure what the pricing would be like for either that or SLS with them.

It’s cool you have one at work, though. I’m assuming it’s an SLS printer?

I’ve had good results with CF nylon on my desktop FDM printers, I wish I had an MJF at my disposal though!

[EuroxS4]

My understanding is the cost of the aluminum powder is crazy high. We are getting a 3D printer at work on consignment, crazy expensive. I have offered to provide sample models to test it with. So far no takers. I have seen it used with good results on projects I have been on but too expensive for my own stuff. I have had good results with 3D printed nylon (MJF).

I have some ideas for 07K swap parts.

[Kevin C]

I worked at HP on their 3D printer project and got hooked on MJF. Since I left HP I have been using a company called rapid made for mjf. A $100 gets you a decent sized part.

The company I'm at now make lasers for SLS so it makes sense to get a printer to test our lasers on.

I also use proto labs. It depends on the project and the material. Lots of options, proto labs is decent

[EuroxS4]

I worked at HP on their 3D printer project and got hooked on MJF. Since I left HP I have been using a company called rapid made for mjf. A $100 gets you a decent sized part.

The company I'm at now make lasers for SLS so it makes sense to get a printer to test our lasers on.

I also use proto labs. It depends on the project and the material. Lots of options, proto labs is decent

I will keep that in mind. I have a few parts I would like to print for testing

[fR3ZNO]

I worked at HP on their 3D printer project and got hooked on MJF. Since I left HP I have been using a company called rapid made for mjf. A $100 gets you a decent sized part.

The company I'm at now make lasers for SLS so it makes sense to get a printer to test our lasers on.

I also use proto labs. It depends on the project and the material. Lots of options, proto labs is decent

That’s awesome. I’ve been getting ads for polyjet stuff from Xometry, the detailed multi color prints are pretty mind blowing.

Yeah, Proto labs isn’t bad at all. I’ve looked into them a couple times for work but their tolerances are a bit looser than we need on parts. But for more basic stuff (like a wiper arm adapter, lol) it’s a good option for sure!