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Introduction, Laser Cutting, CNC Routing, and 3D Printing

Hello Guys,

New to this forum and excited to find it! As I have been reading over the forum posts the last few days, there are a lot of great and very smart people here with like minded interests, which is really cool. I hope that I might be able to contribute is some way and add a little value as we get to know each other and share ideas and thoughts. I have the same username here that I have on most of the other forums, so you can see more about me on those, but a very brief intro.

My name is Jason Smith and I live in Meridian, ID and I am retired USAF Flight Engineer and currently a Flight Performance Model (FPM) Software Test Engineer. While that sounds all fancy and stuff, it actually is not. I am basically doing what I did in the Military, I run Flight Performance Charts to test how the manual charts have been digitized and that coding for all calculations is working correctly. The FPM is an "under the hood tool" in the Mission Planning Environment (MPE). The MPE uses the FPM to output flight performance data to the flight crews for mission planning. Enough about profession!

When it come to the hobby, I have been involved with the flying side since 2004 and have build and flown helicopters and airplanes of many shapes and sizes, from 700-800 size pod and boom and scale helicopters to large 250cc radial engine aircraft. However, I have always been fascinated with the glider/sailplane side and recently, within the past couple of years, purchased my first glider which was a FMS 3m Fox and recently had a TM 2.75m Albatross. I enjoyed both of those for what they are and each had its own flying characteristics. One flew close to a sailplane and one flew more like a airplane! Anyway, while waiting on the TM Ventus to come back in stock, I just ordered the TM Samsara from Aloft and looking forward to getting it. I might post a few things about it, but there is already a very good thread that documents it, not sure I would add a lot of value. I do see some opportunities to redesign and improve few things though!

Why choose my first post in this sub-forum? Well, because this is the area I am particularly passionate about, design and manufacturing. There is also some great threads in this sub-forum and the projects are really cool. I am no expert by any means and all self taught and I have tons more to learn. I design in 2D using Draftsight and 3D in Solidworks. I have also been extremely fortunate to be able to purchase equipment over the years. I am now on my third laser cutter, upgraded a little at a time over the past 10 years, and its FSL PS48 with a 48" x 36" area with a 150W laser tube. I am still in the process of setting this up, but have been able to do some test cuts this past week and its going to be an awesome unit. Still waiting on the fume extractor to really get going.

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For the CNC Router I am running a Stepcraft 840 with a bed size of 36" x 24" and this is great for cutting G10, Carbon Fiber, and thicker MDF and Plywood.

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I started with 3D printing around the time I purchased the FMS Fox Glider and it has opened up a whole new world to me. I am still on my first FDM printer and its an older Craftbot 3 and I use a STATPRO Dry Cabinet to keep the PETG dry and results consistent. Actually PETG is the only material I print. I feel it has the best compromise between printability, strength and heat durability for our models. In the last six months I decided to purchase my first Resin printer, Anycubic Photon Mono SE, and its certainly a learning curve, but getting good results with it. Small format, but its all I need for now.

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Please understand, I am not showing all this to brag or say "look at what I have", I have been extremely fortunate to be able to purchase these units and humbled to have them, I mean that sincerely. It took me a long time to save up for them and each has helped me learn and expand my design projects. The only things I have designed for gliders or sailplanes was a transport/setup stand and streamlined servo covers for my 3m Fox glider which I did post on RCG. I hope to be able to design more items for my Samsara if needed and in the future, I really would like to start designing and scratch building by own sailplanes, both vintage wood structure and composite. I am just passionate about this stuff and love to design and build more than flying, honestly.

If I can help with any project you have, where you might not have the capacity in either design or manufacturing, please don't hesitate to reach out. If I don't know it or have not done it before I will let you know, but always fun to learn and share with each other. I know I was excited to find this forum and looking forward to learning from you guys! Its a small hobby and we need to help each other when we can! Thanks for the opportunity to introduce myself and share a little bit. Thanks and talk soon.

Jason
 
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Now that's a workshop. Do you perform guided tours.

Thanks! You are more then welcome to stop by anytime. Its a little crowded when we have the Toy Hauler stored in the RV bay, but still plenty of room and the beer light is always on! Talk soon.
 
Welcome to the forum. Love your cool toys :)
I tried 3d printing for a few months but just lost interest in it. Having to wait forever for my prints, issues with fixing the printer etc. I think in a few years i will try again. The one thing i am loving about having a laser is how quiet it is and no mess vs the wood tools i would use to make the same parts. This allows me to work in my shop in the mornings before my daughter gets up.

@HENNY didnt realize you were over in Australia. Couple of my favorite youtubers are over by you. Andrew Newton over in Geelong and also Big fan of Allen Moore.
 
Welcome to the forum. Love your cool toys :)
I tried 3d printing for a few months but just lost interest in it. Having to wait forever for my prints, issues with fixing the printer etc. I think in a few years i will try again. The one thing i am loving about having a laser is how quiet it is and no mess vs the wood tools i would use to make the same parts. This allows me to work in my shop in the mornings before my daughter gets up.

@HENNY didnt realize you were over in Australia. Couple of my favorite youtubers are over by you. Andrew Newton over in Geelong and also Big fan of Allen Moore.
Thanks for the welcome. The new laser is pretty awesome. My previous laser was the 50W Ebay laser that actually had the 40W tube they were overdriving to meet 50W. I put a 60W SPT tube and power supply in my old unit and it was a much more capable machine. Having 150W is nice and I have not gone over 50% power and it cuts through 1/4" material like butter. They are very quiet machines for sure, actually the fume extractor will be the loudest part! I still get a fair amount of use from the CNC Router, but that is way too loud to run when the family is sleeping still!

I was reluctant to buy a 3D printer and did a bunch of research and spent a little more than I had budgeted with the CraftUnique Craftbot, but I have had zero issues (I better knock on wood now!) with it and it prints almost everyday. I think the thing that helped me is to be patient and don't push the prints too fast and I always use the same type of filament, from the same manufacture all the time, in my case PETG Pro from Matterhackers. The dry cabinet helps too! I mainly use the FDM machine for tools, jigs, brackets, standoff, and other parts that don't require a bunch of detail and the resin is for the detail parts.

Thanks and talk soon.
 
yeah i am assuming my omtech 50w is more like 30 or 40. Already have a 60 or 80w tube selected for whenever this one dies.
How are you liking resin vs regular 3d printing? Is it significantly faster or similar? How does resin price compare to regular 3d printing?
 
yeah i am assuming my omtech 50w is more like 30 or 40. Already have a 60 or 80w tube selected for whenever this one dies.
How are you liking resin vs regular 3d printing? Is it significantly faster or similar? How does resin price compare to regular 3d printing?
I like the resin printer and it works great for highly detailed parts. It is much more simple to operate in my opinion. But the extra post processing step can be messy and add time to the project. I have the wash and cure station Anycubic sells and is certainly a good tool to have keeps the work area cleaner. I think the biggest learning curve for me was the support structure and part orientation, but I ended up buying the Lychee Slicer and use auto support and orientation and it works good for what I am printing, but I am not printing highly detailed mini figures and other gaming or cosplay stuff that has a lot of thin detailed parts. Just detail parts for the models. Resin cost is about the same as a 1Kg spool of FDM filament for standard resin and can get very expensive if you go with some of the exotic engineering resins. I use Siraya Tech Fast and it has worked well for most everything I have done. I also have some Liqcreate Strong-X, but that is $170 a 1Kg bottle and only use it if I am going to make a mold from it for multiple parts. I use that very sparingly! Talk soon.
 
Dang resin printers have come way down in price. Just now looking. I do like the idea of them being much simpler machines, only 1 axis moving. The main issues i had with my previous machine, and this may have been from getting a cheaper unit, was issues with the leveling process, problems with filament feeding and reloading filament, and i really really was uncomfortable with a heating element running while i was asleep or away from home. Looks like i need to look into resin printing in the future.
 
@HENNY didnt realize you were over in Australia. Couple of my favorite youtubers are over by you. Andrew Newton over in Geelong and also Big fan of Allen Moore.
Yes have seen Andrew's Youtube videos. Its a small world these days. Geelong is way over the other side of Melbourne 100km away. He does some great reviews.
 
Dang resin printers have come way down in price. Just now looking. I do like the idea of them being much simpler machines, only 1 axis moving. The main issues i had with my previous machine, and this may have been from getting a cheaper unit, was issues with the leveling process, problems with filament feeding and reloading filament, and i really really was uncomfortable with a heating element running while i was asleep or away from home. Looks like i need to look into resin printing in the future.
They have come down in price for sure and they are so much simpler than the FDM Machine. There is still a leveling process with most Resin printers, but it's very simple and once set, its good, unless you bump or hit it. The CraftBot 3 is a direct drive vs the Bowden tube system a lot of machines use and that was one of my main driving factors in purchasing the Craftbot 3, so filament feeding has really been a non-issue for me. I don't have auto level, but I have a removable build plate and typically only relevel once a week, just to check, most of the time it has not changed. I also use PrintBite+ for my build surface and once the part cools, it just pops off the build plate. It was certainly a learning curve to get consistent results with the PETG, but once I got it dialed in, it was good to go. I know what you mean on the heating element, I had the same concerns, but now, I typically set up the machine to run when we are sleeping and gone now. Some prints take 20-30 hours. I have that much confidence in the machine. I am shopping around for a little larger machine and have been looking at Raise 3D printers and a few others. I would like to get more capacity to start creating my negative molds right on the 3D printer, so it saves on making the plug. That is the process I will use for a composite glider when and if I get around to designing and building one. A YouTuber that I follow is RamyRC and he has done some remarkable work with giant scale airliner construction using his 3D printers to create the negative molds. Really cool stuff, I would check him out on YouTube.'

If you have any question on a Resin printer or 3D please don't hesitate to reach out. I am no expert, but have done my fair share of research.
 
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If i was interested in just making bucks for vacuum forming servo covers etc what resin would be good. Not manufacturing tons of copies just a few copies here and there. And how much infil do you think?
 
Jason,

I love the shop - Mine will never be that clean, but I can dream. You will have to post some photos of the stuff you are making.

Nathan -

My first FDM printer I thought was pretty good, it gave OK results, etc. The vast majority of things I printed with it were fixes for itself. :( The amount of time tweaking and adjusting and upgrading were endless. Ultimately it was a hobby you had to stay on top of. I thought that was the nature of at home 3D printing. I enjoyed it at the time. Then a customer started showing off his prints and I was blown away. I asked him about detailed setups and calibration processes and he simply replied that he bought the same printer as his buddy and ran it as it came from the factory! I thought he must be messing with me, but then I started reading up on his brand, Prusa. Basically Prusa is one of the key players that made FDM at home possible and he heavily invests in quality control and software refinements with calibrations for popular materials. He is always trying to make his products better. I ended up buying their new "mini" when it was announced and I have been in love with it ever since. The quality of the prints is great and it just keeps working. We seldom have to do anything with it. We ended up buying 3 more, 2 more for the shop and Chris took one home. They are constantly improving their softwares, and that is really key to any company in this category. You can't rely on some generic software application and expect trouble free 3D printing results. Also, Prusa uses a lot of 3D printed materials for their machines, I think they operate the world's largest 3D print farm, so they have a ton of experience in this area.
 
Jason,

I love the shop - Mine will never be that clean, but I can dream. You will have to post some photos of the stuff you are making.

Nathan -

My first FDM printer I thought was pretty good, it gave OK results, etc. The vast majority of things I printed with it were fixes for itself. :( The amount of time tweaking and adjusting and upgrading were endless. Ultimately it was a hobby you had to stay on top of. I thought that was the nature of at home 3D printing. I enjoyed it at the time. Then a customer started showing off his prints and I was blown away. I asked him about detailed setups and calibration processes and he simply replied that he bought the same printer as his buddy and ran it as it came from the factory! I thought he must be messing with me, but then I started reading up on his brand, Prusa. Basically Prusa is one of the key players that made FDM at home possible and he heavily invests in quality control and software refinements with calibrations for popular materials. He is always trying to make his products better. I ended up buying their new "mini" when it was announced and I have been in love with it ever since. The quality of the prints is great and it just keeps working. We seldom have to do anything with it. We ended up buying 3 more, 2 more for the shop and Chris took one home. They are constantly improving their softwares, and that is really key to any company in this category. You can't rely on some generic software application and expect trouble free 3D printing results. Also, Prusa uses a lot of 3D printed materials for their machines, I think they operate the world's largest 3D print farm, so they have a ton of experience in this area.

Thanks Wayne, I have OCD real bad and I am that guy who puts all the tools away and cleans up at the end of working for the day! Its that bad! I will certainly share what I am making with the group here if there is interest! I have tons of ideas in my head for sure.

I would also like to add the recommendation on Prusa printers, absolutely top quality and they are innovators in the field for sure. I was actually between the Prusa and CraftBot when I was deciding, but wanted the enclosed chamber. At the time I thought I would be printing more ABS and having a heating chamber is important, but the PETG has been doing so well in so many different applications, that I don't see the need to switch. I also thought I would use the dual heads and in all honesty, I don't, I only use one head on my unit and the other just sits there for the ride! Nathan, if you pick up a Prusa you can't go wrong! I would certainly buy one. I have thought about it more than once recently.
 
If i was interested in just making bucks for vacuum forming servo covers etc what resin would be good. Not manufacturing tons of copies just a few copies here and there. And how much infil do you think?

The Siraya Tech Fast would work great. If I were doing servo covers to mold, I would make them solid to be honest and it adds zero extra time on a Resin Printer.
 
Nathan, if you pick up a Prusa you can't go wrong! I would certainly buy one. I have thought about it more than once recently.

I second that, had a Prusa MK3 for almost 3 years now, the only few issues I had with the printer were entirely my fault. It worked right off the start, no fiddling and constant tweaking needed. I recently upgraded it to the latest version and added the multi-color option, also built an enclosure for it based on the Ikea Lack tables. That took a lot of printing time for the corner pieces etc., but it keeps the printer dust free. Put the whole thing on wheels and have room to store the filament underneath the enclosure. This makes for a nice compact and moveable setup that doesn't get in the way.

Ralf
 
Picked up a Anycubic photon zero for $99. Pretty impressed with the resolution. Dealing with the resin isn't that big a deal I've got a couple pickle jars with some mean green degreaser and a toothbrush and a little DIY from board box I made to cure. 5, 15, 30 epoxy resin has a thousand times worse smell like the resin smelled from this doesn't even bother me and it doesn't permeate my office at all. There's quite a significant difference in slicing these verses filament soak still kind of wrapping my head around this. The interesting thing too is that it does an entire layer at the same time so percentage of fill or how many things you have printing out at the same time doesn't make any difference to how long the prints going to take. The single factor of how long are prints going to take is how tall your model is. So you could be doing one model and let's say that takes two hours. Well if you can fit 10 of those on your bed next to each other it's still going to take 2 hours. And if you build a piece with 2% and fill that's going to take exactly the same amount of time as 100% infill.

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Yeah the usuall price for the larger units is $300 range. for $99 i felt i could buy it and if i lost interest i would not feel too bad.
 
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