WEBVTT 00:00:00.000 --> 00:00:06.480 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 00:00:07.120 --> 00:00:11.720 I'm actually metal 3d printing some parts for a student team that I'm on 00:00:12.840 --> 00:00:16.280 Linus tech tips is nice enough to sponsor us for these parts 00:00:16.280 --> 00:00:19.720 I'm gonna tell you guys all about what the parts are what they do and 00:00:20.160 --> 00:00:26.600 Why it's so useful to have a machine like this a metal 3d printer versus a traditional five-axis CNC or 00:00:27.000 --> 00:00:31.560 Other manufacturing processes. It's a student team called McMaster Baja Racing 00:00:31.560 --> 00:00:37.200 What we do is we build an off-road single seat race car and it's completely student designed 00:00:37.200 --> 00:00:41.520 It's student manufactured is only a few parts on the car that we have to outsource 00:00:41.920 --> 00:00:47.280 Such as these parts and there are more complicated parts that need the complicated geometries 00:00:47.520 --> 00:00:51.440 so everything is built by the students designed by the students and 00:00:51.960 --> 00:00:59.400 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 00:00:59.400 --> 00:01:04.800 But like seven inches of suspension travel, so it's meant to go over rocks jumps crazy things 00:01:04.800 --> 00:01:08.840 So at competition we go over like massive pieces of wood 00:01:09.040 --> 00:01:12.040 There's sometimes six-foot drops that our car has to survive 00:01:12.080 --> 00:01:17.080 So doing things like this pretty routine for our team and we have to build super strong parts that can 00:01:17.400 --> 00:01:21.480 Last a competition like that. So if you look at these parts 00:01:22.040 --> 00:01:25.200 The angle on these ramps is actually a compound angle 00:01:25.280 --> 00:01:30.160 So if you were to look at it from this perspective and kind of rotate it 00:01:30.200 --> 00:01:36.160 This line stays on you such that if there was a bearing riding on this 00:01:36.160 --> 00:01:40.040 It would ride with a line contact throughout the whole ramp 00:01:40.720 --> 00:01:45.080 so because of this there's a compound angle here it curves in two planes and 00:01:45.560 --> 00:01:49.040 Because of that the only way to manufacture this with a traditional 00:01:49.920 --> 00:01:57.640 Machining process is a five-axis CNC that can rotate in two directions at once and cut and that part costs us 00:01:57.800 --> 00:02:01.680 $60 in material and a hundred and thirty five dollars from our 00:02:02.120 --> 00:02:07.480 Student machine shop at the University and because of this metal 3d printer we can print 00:02:07.920 --> 00:02:12.640 This part for about twenty dollars and have it ready the next day 00:02:12.640 --> 00:02:16.120 So this machine is really great and allows us to get 00:02:16.560 --> 00:02:23.360 Super difficult geometries that are either expensive or impossible in other manufacturing processes 00:02:23.360 --> 00:02:28.280 So how many of these parts do you need for your car? So if you look we've already printed two 00:02:28.920 --> 00:02:34.800 And these have different ramps. So this one is a much steeper ramp. It's a progressive ramp 00:02:34.800 --> 00:02:39.400 It starts off pretty slow at 30 degrees and ramps all the way up to 45 00:02:39.720 --> 00:02:44.840 Well, this one is a linear 30 degree so it's a 30 degree across the entire ramp and 00:02:45.240 --> 00:02:48.520 These different ramp geometries actually have a very different 00:02:48.880 --> 00:02:55.000 Tune in our transmission. So these parts are for the secondary CVT in our transmission 00:02:55.000 --> 00:03:01.280 So a CVT is a continuously variable transmission and essentially what it is is we have a rubber belt on 00:03:01.720 --> 00:03:05.040 Pulleys and those pulleys can expand and contract 00:03:05.200 --> 00:03:09.120 So as they expand or contract the belt falls or 00:03:09.880 --> 00:03:13.720 Rises within the pulley and because of that the gear ratio changes 00:03:13.720 --> 00:03:20.040 So between our most closed state and our most open state we have a continuously variable 00:03:20.840 --> 00:03:30.320 Transmission ratio that we can go between and what these do is these provide a feedback for the secondary the output shaft of this 00:03:31.200 --> 00:03:35.120 transmission and the ramp geometry the 00:03:35.320 --> 00:03:38.000 Tan of the angle is equal to the 00:03:38.880 --> 00:03:43.040 Side the belt clamping force given in this direction 00:03:43.120 --> 00:03:52.960 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 00:03:53.080 --> 00:03:56.760 Secondary CVT, which is what we're looking at right here. And if I just 00:03:57.600 --> 00:04:02.440 You can see this is right here. This is that this is what we printed that ramp geometry is right there 00:04:02.560 --> 00:04:12.540 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 00:04:12.640 --> 00:04:16.320 These rubber belts work in a pulling fashion the primary 00:04:16.760 --> 00:04:23.520 Squeezes and pulls and the secondary squeezes and grabs because of that. We have different geometries and you can think of it 00:04:24.600 --> 00:04:29.160 Kind of like a hill for these bearings to ride on so as the hill gets steeper 00:04:29.280 --> 00:04:32.320 It's harder for it to ride on and it'll provide 00:04:33.000 --> 00:04:38.920 More clamping and because of that we might want more clamping right as we start accelerating 00:04:38.920 --> 00:04:44.000 And then as we're done accelerating at the end of our shift all the way in sixth gear in a manual 00:04:44.080 --> 00:04:47.720 Which would be the top here you want less clamping because you want less 00:04:48.320 --> 00:04:53.640 Efficiency losses so that you can get to those higher speeds. It's a really really simple 00:04:53.720 --> 00:04:56.920 But really really intricate part that kind of 00:04:57.400 --> 00:05:05.160 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 00:05:05.320 --> 00:05:11.720 Was because it's $20 per part we can print a whole ton of parts and we don't have to worry 00:05:12.520 --> 00:05:19.800 About how possible the geometry is to make on a CNC the printer will just print it and any layer lines 00:05:19.800 --> 00:05:25.640 We can just sand away so Yeah, that's kind of most of the information about the part 00:05:26.240 --> 00:05:33.280 And the team and how does the process of taking something from this cad right here into the middle of 3d printer work? 00:05:33.400 --> 00:05:41.120 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 00:05:41.800 --> 00:05:49.480 We actually have Equations here and we can change these starting and ending angles. So I can go from 00:05:50.200 --> 00:05:57.240 A starting angle of 30 in an angle ending angle of 46 to a 46 to 30 and this cad will actually 00:05:58.120 --> 00:06:02.360 Hopefully automatically rebuild No breaking 00:06:02.360 --> 00:06:09.160 Yay So you can see that the cad updated and now we have different angles super easily and we can try different things 00:06:09.560 --> 00:06:16.520 From that all we do is we save it As an stl just like you would for any 3d printing process 00:06:17.240 --> 00:06:23.480 Uh, and then we bring it into a rapidius version of kira. So kira is a metal three or a 3d printing slicer 00:06:24.200 --> 00:06:27.080 Very common and all we do is we bring our part in 00:06:27.720 --> 00:06:31.160 and We don't want to print it like that 00:06:31.320 --> 00:06:36.760 So, uh, we just place it down. We can arrange it. So it's in the center 00:06:37.480 --> 00:06:41.400 We can change all of our settings here, but um, the 00:06:41.640 --> 00:06:44.680 Uh, settings that were already on seem to work pretty well 00:06:45.320 --> 00:06:47.320 All we do really is we hit slice 00:06:48.520 --> 00:06:53.720 That'll make this part into, um, a whole ton of different slices 00:06:54.360 --> 00:06:59.000 Uh, layer by layer just like every other Uh, fdm 3d printing process 00:06:59.720 --> 00:07:02.200 We save this file to, uh 00:07:03.960 --> 00:07:10.280 To our disc and then there's a online tool by rapidia that's hosted by the machine 00:07:11.000 --> 00:07:13.320 And uh, all we do is we give it the gcode 00:07:14.040 --> 00:07:18.840 We let it render it'll load up the gcode now. It says ready to print all we do 00:07:19.480 --> 00:07:24.680 We hit start Uh, you can see the bed is going to warm up pretty soon. It's still at zero 00:07:24.760 --> 00:07:28.600 But so once that gets up to 40 degrees the printer will just start printing 00:07:28.680 --> 00:07:32.440 And is this guy right here the only thing that you have to 3d metal print? 00:07:32.520 --> 00:07:35.640 Or is it more efficient to manufacture the other parts in a different way? 00:07:35.720 --> 00:07:40.040 The point of the team is experience for the students, right? So, um 00:07:40.520 --> 00:07:45.560 A lot of the parts Maybe could be metal 3d printed or it might even be cheaper 00:07:45.560 --> 00:07:48.840 A lot of the times to send it out to a machine shop and have someone else do it 00:07:48.920 --> 00:07:51.560 But getting those students the experience of 00:07:52.200 --> 00:07:55.640 Machining of designing a part and being like, oh my god 00:07:55.960 --> 00:08:03.240 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 00:08:03.480 --> 00:08:07.720 They would look at you and say this is just impossible to make or 00:08:08.200 --> 00:08:12.680 The setup will be insane and you need like three arms to be able to do it 00:08:12.840 --> 00:08:18.200 It gives the students a real understanding of how to design parts not only for 00:08:18.520 --> 00:08:23.160 For them to be working in their assemblies, but also designed for manufacture, which is a really big 00:08:23.640 --> 00:08:29.240 Aspect of modern engineering So we can print a lot more parts in the metal 3d printer 00:08:29.560 --> 00:08:32.200 But we would rather simplify our parts 00:08:32.680 --> 00:08:38.280 Make them on a manual lathe or manual mill The other aspect is our team is based in ontario 00:08:38.600 --> 00:08:41.800 So if a part breaks, we don't want to have to come back here 00:08:42.280 --> 00:08:45.480 Especially if it's close to competition. We only have one week to go 00:08:46.280 --> 00:08:50.200 Making simple easy to manufacture parts means if something breaks 00:08:50.600 --> 00:08:57.800 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 00:08:57.960 --> 00:09:04.440 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 00:09:04.520 --> 00:09:09.480 Different things or you want to try like complicated features in different ways, but for most of the car 00:09:09.560 --> 00:09:16.920 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? 00:09:17.080 --> 00:09:22.520 So they're actually actively building the car. This is actually our first weld that we laid down 00:09:22.920 --> 00:09:25.800 This last week. So this is our chassis 00:09:26.440 --> 00:09:29.320 So we're actively manufacturing as we speak 00:09:29.560 --> 00:09:36.760 So the goal is to get the car done for Laval University of Laval has a competition in Quebec City 00:09:37.240 --> 00:09:45.400 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 00:09:46.040 --> 00:09:53.400 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 00:09:54.040 --> 00:09:58.520 Uh, but yeah, that's kind of the goal and then in terms of the rest of the year 00:09:58.520 --> 00:10:03.560 So that's a regional competition. That's not an official competition. So that's more just for fun 00:10:04.120 --> 00:10:08.600 So that everyone can kind of test our car out in the snow. The official competitions are all during the summer 00:10:08.600 --> 00:10:12.920 So our first one is end of april and then we have one sometime in may 00:10:13.160 --> 00:10:18.840 That's where our car really matters and from February until then it's all testing 00:10:18.920 --> 00:10:24.440 So we want to try out all these different helixes. We want to try out different, uh, suspension setups 00:10:24.440 --> 00:10:30.120 We want to try out all these different little characteristics of our car and make them the best that we can 00:10:30.200 --> 00:10:37.800 So that's only step one of the process. So these are called green parts and they are clay like, uh, very, uh, powdery 00:10:38.360 --> 00:10:43.640 Uh parts and what we do is we take these parts and we sand down these layer lines for the bearing 00:10:43.800 --> 00:10:48.440 May not look like it, but that feels super smooth to the touch and we put it in this machine here 00:10:49.000 --> 00:10:57.320 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 00:10:57.800 --> 00:11:04.040 Of the steel such that the particles will attach together and kind of melt together into one solid part 00:11:04.120 --> 00:11:09.320 And then it cools it down. It does this in an argon environment. So nothing really goes wrong 00:11:09.800 --> 00:11:14.920 Uh, but out of this machine we get our finished part. So step one and step two 00:11:15.080 --> 00:11:19.720 So it's the next day. Uh, we have our centered parts here, uh, ready for 00:11:20.520 --> 00:11:26.840 Uh, putting it in the car. So you can see this is a green part before it's been centered and a centered part 00:11:27.320 --> 00:11:34.200 Uh, you see the size difference. So rippitya one of the best things about it is it does all that shrinkage math for you 00:11:34.200 --> 00:11:38.280 So there's multiple axes of shrinkage something that is 00:11:38.840 --> 00:11:44.280 Wide and flat like the bottom of this versus these parts right here might shrink in different dimensions 00:11:44.680 --> 00:11:47.480 But the software automatically calculates all that for you 00:11:48.040 --> 00:11:51.960 So we have super accurate super clean parts ready to go 00:11:52.520 --> 00:11:55.960 And these are all sanded down. So it's super nice for the bearings 00:11:56.520 --> 00:12:02.520 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 00:12:02.840 --> 00:12:06.600 So why did this one fail right here? That failed actually due to me 00:12:06.920 --> 00:12:11.240 I put this outside the print volume of the printer and that's why the line is so straight 00:12:11.720 --> 00:12:14.840 So it was just too far to the left on one of the sides 00:12:15.320 --> 00:12:21.640 And physically the printer couldn't go there. So it was completely user error. Uh, it's my first time using the machine. So 00:12:22.200 --> 00:12:24.840 Um, yeah overall this machine has been 00:12:25.560 --> 00:12:28.920 Super good super easy to use once you get past a few little hurdles 00:12:29.160 --> 00:12:33.000 Hopefully the next thing we can show you guys is this part actually running in the car 00:12:33.240 --> 00:12:38.920 We have an engine uh and transmission dynamometer that we built ourselves that you might be able to see this in too 00:12:39.320 --> 00:12:44.280 So, uh, can't wait to show you guys this part running in the car making it go real fast 00:12:48.040 --> 00:12:53.960 Something else really interesting that the 3d printing process allows us to do and the reason we were so excited about it 00:12:54.200 --> 00:12:59.080 Was trying all these different angles You can see each one has a label this one 00:12:59.080 --> 00:13:03.400 You can see it starts at a super low angle and goes up to a really really steep angle 00:13:03.880 --> 00:13:07.640 While this one starts at a steep angle and goes to a low angle 00:13:07.880 --> 00:13:14.440 So this process allows us to try all these different types of angles very simply and very easily all those 00:13:15.160 --> 00:13:19.720 Have different tunes on the transmission of the car due to the forces we talked about before 00:13:20.200 --> 00:13:26.600 So we're really excited to be able to try Five different helixes, which we've never done before. We always just have one