The making of a viaduct..

Here's the place for discussions about those 3D creations for Tguage...and lets not forget the trials and tribulations of designing and printing.
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dkightley
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Re: The making of a viaduct..

Post by dkightley »

I've reached the point of readiness for printing.

I'll need four six arch sections:
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Four six arch road sections:
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Stonework and a short road sections for one end:
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And stonework and a short road section for the other end:
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And here's the whole viaduct in all it's glory:
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It'll take a while to print....I'll have to schedule the printing very carefully. Each six arch section will take over 20 hours to print!! :shock:
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

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JBModels
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Re: The making of a viaduct..

Post by JBModels »

It looks well..... 20 hours!! A pretty long time.
LOL! Some people need a to think logically, or rather just have common sense!

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dkightley
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Re: The making of a viaduct..

Post by dkightley »

Here's one reason why 3D printing is not actually a "breakthrough" for mass-production.....but an asset for prototyping.

For example a Lego brick that takes 15 seconds to make (along with half a dozen other similar bricks) by injection moulding (where 14 of those seconds is cooling time!) can take as long as 15 minutes to make on a typical FFF 3D printer. The big difference that does matter is the cost. To injection mould one sample new brick would cost in excess of £10,000 in tooling and labour costs.....but less than £20 in labour costs to 3D print, and it can be re-designed and re-printed many, many times in the same time it woukd take to produce one set of moulding tools..

Coming back to the subject in hand, yes, 20 hours is a long time. But in terms of what the printing process is, we're looking at a lot of work the printer has to do....and it doesn't really matter how long it does take providing the end product is good quality and unique!

I'm actually setting up to print the stonework sections from files I'll be writing and copying to a SD card reader in the printer....so I don't need to have my PC connected and running during the print process.
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

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Nutter
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Re: The making of a viaduct..

Post by Nutter »

Very interesting regarding print times, however it will look good when finished , when will you get back to updates on the bridge.
Mike
DON'T knock it at least I am trying to do something, with only one good hand.

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JBModels
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Re: The making of a viaduct..

Post by JBModels »

There's also the option of making 1 or 2 master prints and then making moulds for resin cast stuff too. The good thing is that with multiple moulds you can cast multiple objects and speed up the process in case you want to sell stuff like this.

I'd prefer the 3D printing method also no matter what the time is.
LOL! Some people need a to think logically, or rather just have common sense!

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dkightley
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Re: The making of a viaduct..

Post by dkightley »

Nutter wrote:...when will you get back to updates on the bridge
I've had a rather busy and exhausting time over the past few weeks; preparing for and running a 7 day WW2 event at the Museum, clearing up afterwards, and manning a 3D printing demonstration at a models event at the museum over last weekend. Today I've just about managed to get the house straight ( ;) :roll: :shock: ) so I can now start concentrating again on The Bridge again. With something like 10 months to it's first booked outing, I need to crack on with it!
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

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dkightley
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Re: The making of a viaduct..

Post by dkightley »

Managed to get a bit of print time in for this project...

Here's the two small end rail deck sections and one of the viaduct end sections:
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And here's one of the rail deck sections in place on top of the end section:
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Most of this will be buried under the ground surface...this bit is the very end of the viaduct and the viaduct proper will go off to the right
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

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dkightley
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Re: The making of a viaduct..

Post by dkightley »

First of the rail deck sections fresh off the printer:
IMG_2194_red.JPG
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This wasn't actually the first one to be printed...it's the third! The first two suffered one of the big problems with fff printing - separation from the bed!

What happens is that as the plastic cools, it wants to contract, and this contraction sets up terrific stresses in the plastic that can "curl" the extremities away from the bed.....resulting in a print that can be best described as "banana shaped". One cure...as you can see I have used here....is to add "mouse ears" (the name coined from Mickey Mouse, btw!!) to the corners to increase the surface area in contact with the bed to stop the curling. Because I have been using a raft, I simply had to add the mouse ears to the raft by dropping in small discs. Where a raft is not used, the ears would have to be attached to the part being printed.

All I need to do to finish this section is carefully prise off the raft and the support structure underneath....and remove the support inside the track grooves. And not forgetting, print the other three.....
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

barneyadi
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Re: The making of a viaduct..

Post by barneyadi »

Looking great Doug, keep up the good work.

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dkightley
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Re: The making of a viaduct..

Post by dkightley »

After a marathon of just under 15 hours printing, hot off the press is the first of four six-arch sections:
IMG_2197_red.JPG
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It's still stuck to the build plate and has all its supports underneath the arches.

After several light taps with a chisel handle, the section released from the build plate....and the support came away nice and easily. And less than 5 minutes after the above shot, here's the section roughly assembled with it's rail deck...and the viaduct end section:
IMG_2199_red.JPG
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Three arch sections and t'ther end to go!....having got all four of the rail deck sections printed.
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

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Nutter
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Re: The making of a viaduct..

Post by Nutter »

Wow, that will look impressive on a layout.
Mike
DON'T knock it at least I am trying to do something, with only one good hand.

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dkightley
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Re: The making of a viaduct..

Post by dkightley »

Getting there.....

Here's the current state of printing:
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All four rail decks printed, both end sections & decks, and three of the arch sections. The fourth is just starting to take shape in the printer....should be done in the morning (in about 16 hours time!!).

Notice the pile of scrap support sitting in the printer frame...that'll end up in a pretend sandbag at the Tramway Museum.
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

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dkightley
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Re: The making of a viaduct..

Post by dkightley »

When I finally deliver the viaduct to Dave, I think I'll have to throw in a set of these:
Img_1668_red.jpg
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These are spacers that press onto the track and are designed to keep flexitrack at the right spacing ( relating to approx. 6 foot spacing )...which happens to be the same spacing as I've used on the rail deck. They also can be used to set the right placement of platform edges.
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

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JBModels
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Re: The making of a viaduct..

Post by JBModels »

That's looking lovey....
LOL! Some people need a to think logically, or rather just have common sense!

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dkightley
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Re: The making of a viaduct..

Post by dkightley »

And, finally, the viaduct is complete:
IMG_2218_red.JPG
IMG_2218_red.JPG (52.93 KiB) Viewed 8183 times
Each section is made up of two parts - the stonework and the rail deck.


Here's some photos of the viaduct assembled and showing some of the detail:
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Img_2213_red.jpg (94.32 KiB) Viewed 8183 times
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

mattd10
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Re: The making of a viaduct..

Post by mattd10 »

What a beautiful structure. Superb work once again Doug. Also loving the track spacer/platform jig. I'd definitely be interested in one of those. On a semi-related note, do you still have your online shop?

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dkightley
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Re: The making of a viaduct..

Post by dkightley »

The viaduct is finally on its way to the customer.....delayed only because he asked me to hang onto it for a couple of weeks.

Interesting facts....approx. 420g of plastic filament used and a total printing time somewhere in excess of 56 hours And at present, this is the largest 3D product I have made.....at the moment, that is. There is a larger product in the making. ;)
Doug Kightley
Webmaster here and volunteer at the National Tramway Museum http://www.tramway.co.uk

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Re: The making of a viaduct..

Post by JBModels »

It looks beautiful....!
LOL! Some people need a to think logically, or rather just have common sense!

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