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Messing around with the metal 3d printer, are you? Yeah. Yeah, so I'm a wall. I'm a student testing analyst at the lab and

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I'm actually metal 3d printing some parts for a student team that I'm on

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Linus tech tips is nice enough to sponsor us for these parts

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I'm gonna tell you guys all about what the parts are what they do and

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Why it's so useful to have a machine like this a metal 3d printer versus a traditional five-axis CNC or

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Other manufacturing processes. It's a student team called McMaster Baja Racing

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What we do is we build an off-road single seat race car and it's completely student designed

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It's student manufactured is only a few parts on the car that we have to outsource

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Such as these parts and there are more complicated parts that need the complicated geometries

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so everything is built by the students designed by the students and

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Raced by the students what you're telling me you guys jumped over a car. Yeah, so our car is an off-road car with

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But like seven inches of suspension travel, so it's meant to go over rocks jumps crazy things

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So at competition we go over like massive pieces of wood

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There's sometimes six-foot drops that our car has to survive

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So doing things like this pretty routine for our team and we have to build super strong parts that can

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Last a competition like that. So if you look at these parts

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The angle on these ramps is actually a compound angle

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So if you were to look at it from this perspective and kind of rotate it

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This line stays on you such that if there was a bearing riding on this

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It would ride with a line contact throughout the whole ramp

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so because of this there's a compound angle here it curves in two planes and

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Because of that the only way to manufacture this with a traditional

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Machining process is a five-axis CNC that can rotate in two directions at once and cut and that part costs us

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$60 in material and a hundred and thirty five dollars from our

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Student machine shop at the University and because of this metal 3d printer we can print

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This part for about twenty dollars and have it ready the next day

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So this machine is really great and allows us to get

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Super difficult geometries that are either expensive or impossible in other manufacturing processes

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So how many of these parts do you need for your car? So if you look we've already printed two

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And these have different ramps. So this one is a much steeper ramp. It's a progressive ramp

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It starts off pretty slow at 30 degrees and ramps all the way up to 45

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Well, this one is a linear 30 degree so it's a 30 degree across the entire ramp and

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These different ramp geometries actually have a very different

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Tune in our transmission. So these parts are for the secondary CVT in our transmission

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So a CVT is a continuously variable transmission and essentially what it is is we have a rubber belt on

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Pulleys and those pulleys can expand and contract

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So as they expand or contract the belt falls or

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Rises within the pulley and because of that the gear ratio changes

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So between our most closed state and our most open state we have a continuously variable

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Transmission ratio that we can go between and what these do is these provide a feedback for the secondary the output shaft of this

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transmission and the ramp geometry the

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Tan of the angle is equal to the

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Side the belt clamping force given in this direction

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So I actually have the assembly here This is where the engine mounts and that is the output shaft of our engine here and then from this it goes out to our

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Secondary CVT, which is what we're looking at right here. And if I just

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You can see this is right here. This is that this is what we printed that ramp geometry is right there

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so those bearings ride and What they do is they provide clamping on the belt and you need to clamp this rubber belt so that the torque can be transferred

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These rubber belts work in a pulling fashion the primary

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Squeezes and pulls and the secondary squeezes and grabs because of that. We have different geometries and you can think of it

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Kind of like a hill for these bearings to ride on so as the hill gets steeper

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It's harder for it to ride on and it'll provide

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More clamping and because of that we might want more clamping right as we start accelerating

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And then as we're done accelerating at the end of our shift all the way in sixth gear in a manual

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Which would be the top here you want less clamping because you want less

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Efficiency losses so that you can get to those higher speeds. It's a really really simple

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But really really intricate part that kind of

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Characterizes where we can go in our transmission what this metal 3d printer allows us to do and the reason we were so excited to use it

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Was because it's $20 per part we can print a whole ton of parts and we don't have to worry

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About how possible the geometry is to make on a CNC the printer will just print it and any layer lines

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We can just sand away so Yeah, that's kind of most of the information about the part

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And the team and how does the process of taking something from this cad right here into the middle of 3d printer work?

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So that's actually super simple so here I have the cad for the for this helix is what we call it because it's like a helical angle and

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We actually have Equations here and we can change these starting and ending angles. So I can go from

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A starting angle of 30 in an angle ending angle of 46 to a 46 to 30 and this cad will actually

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Hopefully automatically rebuild No breaking

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Yay So you can see that the cad updated and now we have different angles super easily and we can try different things

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From that all we do is we save it As an stl just like you would for any 3d printing process

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Uh, and then we bring it into a rapidius version of kira. So kira is a metal three or a 3d printing slicer

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Very common and all we do is we bring our part in

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and We don't want to print it like that

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So, uh, we just place it down. We can arrange it. So it's in the center

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We can change all of our settings here, but um, the

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Uh, settings that were already on seem to work pretty well

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All we do really is we hit slice

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That'll make this part into, um, a whole ton of different slices

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Uh, layer by layer just like every other Uh, fdm 3d printing process

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We save this file to, uh

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To our disc and then there's a online tool by rapidia that's hosted by the machine

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And uh, all we do is we give it the gcode

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We let it render it'll load up the gcode now. It says ready to print all we do

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We hit start Uh, you can see the bed is going to warm up pretty soon. It's still at zero

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But so once that gets up to 40 degrees the printer will just start printing

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And is this guy right here the only thing that you have to 3d metal print?

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Or is it more efficient to manufacture the other parts in a different way?

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The point of the team is experience for the students, right? So, um

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A lot of the parts Maybe could be metal 3d printed or it might even be cheaper

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A lot of the times to send it out to a machine shop and have someone else do it

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But getting those students the experience of

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Machining of designing a part and being like, oh my god

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I can't actually make this like if you design this and then brought it to a manual machine shop, which is all we have at university

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They would look at you and say this is just impossible to make or

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The setup will be insane and you need like three arms to be able to do it

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It gives the students a real understanding of how to design parts not only for

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For them to be working in their assemblies, but also designed for manufacture, which is a really big

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Aspect of modern engineering So we can print a lot more parts in the metal 3d printer

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But we would rather simplify our parts

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Make them on a manual lathe or manual mill The other aspect is our team is based in ontario

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So if a part breaks, we don't want to have to come back here

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Especially if it's close to competition. We only have one week to go

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Making simple easy to manufacture parts means if something breaks

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We can go to the lathe remake it and it essentially doesn't cost us any money because we already bought some extra material that we can find lying around the shop

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Yeah, the metal 3d printers are a really great tool for parts like this where you want a whole bunch of different parts to try out

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Different things or you want to try like complicated features in different ways, but for most of the car

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It's just simple cylinders or simple plates that are machined. So we'd rather the students manufacture that and when are you guys going to be building this?

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So they're actually actively building the car. This is actually our first weld that we laid down

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This last week. So this is our chassis

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So we're actively manufacturing as we speak

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So the goal is to get the car done for Laval University of Laval has a competition in Quebec City

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And of January, February 1st to 2nd, I think is the date. So the goal is finished car running under its own power by that date

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Uh We'll see how it goes. We did it last year in this timeline. Uh this year. I haven't been there. So I don't know

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Uh, but yeah, that's kind of the goal and then in terms of the rest of the year

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So that's a regional competition. That's not an official competition. So that's more just for fun

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So that everyone can kind of test our car out in the snow. The official competitions are all during the summer

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So our first one is end of april and then we have one sometime in may

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That's where our car really matters and from February until then it's all testing

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So we want to try out all these different helixes. We want to try out different, uh, suspension setups

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We want to try out all these different little characteristics of our car and make them the best that we can

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So that's only step one of the process. So these are called green parts and they are clay like, uh, very, uh, powdery

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Uh parts and what we do is we take these parts and we sand down these layer lines for the bearing

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May not look like it, but that feels super smooth to the touch and we put it in this machine here

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Uh, we can't show you the inside of it But essentially you can think of it like a big oven and it'll get just close enough to the melting point

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Of the steel such that the particles will attach together and kind of melt together into one solid part

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And then it cools it down. It does this in an argon environment. So nothing really goes wrong

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Uh, but out of this machine we get our finished part. So step one and step two

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So it's the next day. Uh, we have our centered parts here, uh, ready for

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Uh, putting it in the car. So you can see this is a green part before it's been centered and a centered part

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Uh, you see the size difference. So rippitya one of the best things about it is it does all that shrinkage math for you

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So there's multiple axes of shrinkage something that is

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Wide and flat like the bottom of this versus these parts right here might shrink in different dimensions

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But the software automatically calculates all that for you

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So we have super accurate super clean parts ready to go

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And these are all sanded down. So it's super nice for the bearings

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And uh, hopefully in the next uh, little bit, I'm going to go back to the team and get this running in the car

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So why did this one fail right here? That failed actually due to me

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I put this outside the print volume of the printer and that's why the line is so straight

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So it was just too far to the left on one of the sides

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And physically the printer couldn't go there. So it was completely user error. Uh, it's my first time using the machine. So

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Um, yeah overall this machine has been

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Super good super easy to use once you get past a few little hurdles

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Hopefully the next thing we can show you guys is this part actually running in the car

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We have an engine uh and transmission dynamometer that we built ourselves that you might be able to see this in too

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So, uh, can't wait to show you guys this part running in the car making it go real fast

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Something else really interesting that the 3d printing process allows us to do and the reason we were so excited about it

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Was trying all these different angles You can see each one has a label this one

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You can see it starts at a super low angle and goes up to a really really steep angle

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While this one starts at a steep angle and goes to a low angle

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So this process allows us to try all these different types of angles very simply and very easily all those

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Have different tunes on the transmission of the car due to the forces we talked about before

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So we're really excited to be able to try Five different helixes, which we've never done before. We always just have one