New Vendor - 3D Printing

[Dano 1]

Hey everyone, by now some of you have probably seen my build thread or my thread about 3D printed fender tags.

Build thread:
http://www.dodgecharger.com/forum/index.php/topic,131811.0.html
Fender tags:
http://www.dodgecharger.com/forum/index.php/topic,136550.0.html

I've been working on combining my day job as a product development engineer with my Charger project and general car hobby into a side-business designing and producing parts and accessories for our cars. I've geared up with a 3D scanner, CAD software, and two different 3D printers to produce just about anything I or you can dream up. I've been working on parts for my car as I've needed them and my plan is to have a few different off-the-shelf offerings of more universal parts and offer custom design/development services to anyone looking for something unique or one off.

Take a look at the below parts and pieces I've done for my own car to get an idea of capabilities. I plan to update this thread as I get products ready for ordering and would love to get other people's feedback or requests. Feel free to follow along through any of the following:
Website: www.nextgendesignsnc.com
Instagram: @next.gen.designs.
Facebook: Next Gen Designs

Mods feel free to move this thread if it belongs elsewhere.

66-70 B-Body console repair/reinforcement plate
- Matched to the form of the rear portion of the console which is frequently cracked/broken
- Printed in ABS plastic, the same as the base material of the console allowing for easy bonding





Grill repair components
- Reinforcements for broken grill areas
- Printed in ABS plastic, the same as the base material of the grill allowing for easy bonding











Console Gauge Pod
- Houses any two 2-1/16" gauges
- Designed to exactly match the profile of the 66-70 console top plate
- Mounts with high-strength magnets requiring no holes or damage to the console plate and easily removed for shows etc.
- Works with auto or 4-speed consoles

[moparguy01]

What are the sizes your machines are capable of? I am wanting to get a part made to test a design. If it works I will get it made out of aluminum. I would have an stl file to work it.

Russ

[Just 6T9 CHGR]

Dan, this is a great service.   Might I suggest a few more grill repair parts?

On my '69, I recently had to repair the drivers side door stop & pivot point.  The weight of the emblems make these areas susceptible to breakage.

This would work for at least 68 & 69

Also another common break area would be the corner "points" of the grill as well where these fill the bumper gap.

[Dano 1]

What are the sizes your machines are capable of? I am wanting to get a part made to test a design. If it works I will get it made out of aluminum. I would have an stl file to work it.

Russ

I'd be happy to help with that, Russ. My larger machine has a build volume of 9.83in x 8.3in x 8.3in and can do a variety of materials. If your part won't fit in that volume they can often be easily broken up into multiple smaller parts and glued together, especially for proof of concept models. I also have a partnership with a local CNC machine shop owned by a friend of mine so if you'd like any help coordinating getting the part made out of aluminum I'd be happy to help there as well. Shoot me an email - dan@nextgendesignsnc.com and we'll go from there.

Just 6T9 CHGR - Great suggestion on the headlight door stop, I need to check my grill and see if mine are intact or not. I will certainly add that to the list of parts to get designed. I am actually working on the grill corners as we speak. One of mine was intact and the other was broken but I actually found the broken piece in a box of misc. parts in the trunk  . I have a 3D scan of the grill corner and am working on creating a new 3D model of the part to print from, stay tuned!

[Lennard]

Great job Dan!

[Mopar Nut]

 

[Just 6T9 CHGR]

Just 6T9 CHGR - Great suggestion on the headlight door stop, I need to check my grill and see if mine are intact or not. I will certainly add that to the list of parts to get designed. I am actually working on the grill corners as we speak. One of mine was intact and the other was broken but I actually found the broken piece in a box of misc. parts in the trunk  . I have a 3D scan of the grill corner and am working on creating a new 3D model of the part to print from, stay tuned!

You can tell if its broken when you see your door doing the old sag-a-rooski....you will be able to see the headlight at the top behind the door...

Untitled

[Dano 1]

Make a casual suggestion and you shall receive...I had a couple hours yesterday so I checked my headlight doors and found one broken. Luckily the other side was intact so I could measure/document it to generate a CAD model. Quick hour on the printer and we've got some repair parts. I printed them in silver to show the design of the part and how it fits the headlight door. The final parts would be printed in black ASA/ABS plastic, ready to bond.

Broken headlight door stop



CAD model of the repair part



Printed repair part overlaid on the broken door



Side by side comparison of the original headlight door and the mocked up repair



If anyone needs one or both of these just let me know.

[VegasCharger]

Awesome stuff Dan!!! You'll be a fan favorite.

[Kern Dog]

Buy that man a L A P DANCE !
(When the dancing tramps are allowed to frolic around naked again)

[Dano 1]

Thanks for the feedback guys, if anyone has any other requests or suggestions just let me know!

[kent]

You the Man Dan! Thanks for everything!

[Just 6T9 CHGR]

Nice work!  Wish I had this in my hands a few months ago before I busted my azz making my own.

Oh yeah....it IS possible to remove the door with the grill in the car.   Its a bit of a PITA to get the 2 screws on the fender side but it can be done....

[Just 6T9 CHGR]

Actually Dan, I have a question about these.

Is the "tab" part thicker to keep the same plane as if the original piece were there?  If not this will make the door higher since the tab will sit higher on the door..

[bill440rt]

This.
This is awesome stuff. 
I've repaired those headlight tabs for years just like that, fabbing a tab out of metal and rivet bonding it. Then, using adhesive and fillers to make it seamless. Those tabs would be great to have.
Same with the outer grille corners.
Let me know when they are available, thanks! 

[nvrbdn]

Nice work!!

[Old Moparz]

Nice job on the repair parts.  



Wonder where all the naysayers are now?....LOL  

http://www.dodgecharger.com/forum/index.php/topic,109655.msg1345848.html#msg1345848

Older link:
http://www.dodgecharger.com/forum/index.php/topic,82958.0.html

[RallyeMike]

Nice job on this stuff 

[Dano 1]

Thanks for the kind words everyone, stay tuned as I get more parts and designs ready to go.

Nice job on the repair parts. 

Wonder where all the naysayers are now?....LOL   

http://www.dodgecharger.com/forum/index.php/topic,109655.msg1345848.html#msg1345848

Older link:
http://www.dodgecharger.com/forum/index.php/topic,82958.0.html

Nice find Old Moparz, that was before I had my car and any real involvement in the forum. 3d printing technology has come a long way from even 2014, with more and more patents held by the big players in the industry expiring which allows smaller companies to cascade tech down to affordable home machines.

Actually Dan, I have a question about these.

Is the "tab" part thicker to keep the same plane as if the original piece were there?  If not this will make the door higher since the tab will sit higher on the door..

I double checked this on my grill and you were spot on. I went back into the model and added some thickness where the tab contacts the grill frame and a small rib across the top to add some strength. What's amazing about this technology is that I can make a quick tweak in my CAD model and have parts in hand an hour later.

[greycharger]

Is the type of plastic making the grille known? Can it be welded to attach the repair pieces?

[JB400]

Just out of curiosity, why didn't they put it on the bottom of the headlight door instead?

[66FBCharger]

 

[Dano 1]

Is the type of plastic making the grille known? Can it be welded to attach the repair pieces?

The vast majority of plastic parts in these cars are ABS which can be bonded or welded fairly easily. You can also make your own adhesive by dissolving scraps of ABS in acetone to create a 100% like material joint. This is a great use of excess printer filament and scrap parts, I can include some scrap material for making adhesive if that would be of interest.

Just out of curiosity, why didn't they put it on the bottom of the headlight door instead?

That would certainly make sense but my only guess/assumption is they didn't want anything to be visible when the doors are open, or possibly interfere with the grill frame. 

[Mopar Nut]

The vast majority of plastic parts in these cars are ABS which can be bonded or welded fairly easily. You can also make your own adhesive by dissolving scraps of ABS in acetone to create a 100% like material joint. This is a great use of excess printer filament and scrap parts, I can include some scrap material for making adhesive if that would be of interest.

That's a good idea.

[Mopar Nut]

Will you be making reinforcements for areas like in the corners of the grill. Of course for the inside on both sides.