Here is a pic of a bracket I need to duplicate. I figure it needs to be scanned by the 3D scanner but I need some suggestions on how to reproduce the bracket either aluminum or iron. I would imagine it will need to be transferred to a 3D printer or multi cam CNC to make a plug then to a sand cast. Any ideas or questions?
Why scan and print? Just make a mold of the existing part…
1 Like
Because using the original part to make a mold will mean the cast metal part will be anywhere from 5-15% smaller depending upon the metal used to cast it.
Maybe cover with putty for the amounts you think it will shrink. Then make mold and cast, machine the surfaces that need to be machine to dimension.
From this picture it looks easy enough to just model directly in Fusion 360 instead of stitching together a 3D scan. Then just adjust accordingly for shrinkage.
2 Likes
From the picture this item looks larger then our casting equipment will be able to create. Once you have your model, talk with Tom. He has contacts with a local foundry who can pour your piece.
Is this something you need to make more than one of? If it’s just a one-off part, you could probably gin up a functional replacement with a couple of pieces of half-inch plate on the blacksmith anvils, then weld in your braces and hooks. Be fast, and stronger than the original cast part.
1 Like
Thanks for the replies. I need to mention only one has to be made and the one pictured is a one only and I will have to borrow it to scan it and I can only borrow it for a few hours some day soon before it will have to be installed on it’s vehicle. Thanks again fellow Makers.
Depending upon what it is being used for on a vehicle, this piece of information is very important in the material selection. The strength of the material when subjected to various types of stress (tensile, compression, and shear) would be key factors in selecting the material, which will likely dictate the method of production.
From the look of your original, I suspect it is steel and that neither cast iron or aluminum will be strong enough, depending upon what it is actually being used for.
This actually holds two 6 inch gauges and doubles as a structural support that connects to lower plumbing. I have seen some applications where it is connected to a bracket below to help support the bench. Hope this helps. Thanks.
Maybe not as elegant but machine out of a piece if plate with notches for dials.
Easy to fab a functional structural support that gages attach to as long as original look not important.
How elegant to you want it? You could easily make that out of plate in probably an hour.
Thanks for the thoughts. It is 100 years old and it needs to look original. My thought was to scan it while I can still borrow it and worry about how to duplicate it when there is more time. Will saving it with the 3D scanner do that or do I need to get a wax impression instead or something else? You can go to www.chfdalf.org to see the project. You will see there are many projects to be done. Thanks again for all the help and ideas.
I saw the American LeFrance on the gauge face and KNEW I was going to like this project!
I wish I could be more helpful.
My impression? Take a plaster or similar molding of it (i.e. see if you can reproduce it visually in a less-shrinkage-prone medium) and keep that around for working with; something you can repeatedly “play with”. A 3d model would be good, too, but if I could only do one or the other, I’d go for the physical.
If pressed, I agree the welded-up plate steel variety should get you going, but yeah, you’re gonna want to be able to reproduce the look, texture, etc. of the original. It surely cannot be THAT difficult…