Need help with manufacturing this prototype

fatguyslim · Mar 16, 2020

Hey everyone, I am looking to get this prototype made but I am not sure where I can go to get this done in Stainless Steel? I also have a STEP file that shows what it looks like in 3d. The prototype is basically a 7mm rod that is bent on various points to get this shape. Can someone let me know where I can get something like this made?

Milland · Mar 16, 2020

I bet one of our UK members could make you a precision bending fixture such that you could bend your own rods. Might be a better option than trying to have the actual part made, then deciding you need alterations to it.

fatguyslim · Mar 16, 2020

Milland said:
I bet one of our UK members could make you a precision bending fixture such that you could bend your own rods. Might be a better option than trying to have the actual part made, then deciding you need alterations to it.

That would be helpful but I am not sure if I can get the measurements to be accurate

Milland · Mar 16, 2020

fatguyslim said:
That would be helpful but I am not sure if I can get the measurements to be accurate

A proper fixture would include length stops and angle stops. Sure, there'll be some trial and error, and you'll have to decide whether your design is set in stone or could change. If set, then let someone else do it. If iterations may be needed, I'd rather have the fixture and be able to try changes myself.

fatguyslim · Mar 16, 2020

Milland said:
A proper fixture would include length stops and angle stops. Sure, there'll be some trial and error, and you'll have to decide whether your design is set in stone or could change. If set, then let someone else do it. If iterations may be needed, I'd rather have the fixture and be able to try changes myself.

I would definitely prefer making a jig for this, lets hope someone can help me build one.

Peter from Holland · Mar 16, 2020

Let someone with a CNC wire bender do it Alterations are easy to make too

Peter

Dan from Oakland · Mar 16, 2020

Find a shop that does CNC tube bending.

modelmakerblue · Mar 16, 2020

Try Wardown Engineering in Dunstable, Beds they should be able to quote for this.
Tony

fatguyslim · Mar 16, 2020

modelmakerblue said:
Try Wardown Engineering in Dunstable, Beds they should be able to quote for this.
Tony

Thanks Tony will ring them tomorrow

EPAIII · Mar 16, 2020

And without any tolerances on your drawing, no one will know just what accuracy you need. You have designed something, but have not given any thought as to just what those tolerances are, HAVE YOU?

There is an inverse relationship between tolerance and cost. The smaller the tolerance, the higher the cost. The larger the tolerance, the lower the cost.

Unless money is no object, then this is a basic part of design work.

PS: A reasonable inference from your drawing, as it is, would be all linear dimensions are +/-0.1mm and all angular dimensions are +/- 1 degree. But that may or may not work for your part. And do remember that tolerances on multiple dimensions and angles can all add to the maximums or all subtract to the minimums. So three linear dimensions with a 0.1mm tolerance can have an overall +0.3 or -0.3 mm difference. Either of these conditions would be considered to be "in tolerance".

fatguyslim said:
That would be helpful but I am not sure if I can get the measurements to be accurate

Milland · Mar 16, 2020

modelmakerblue said:
Try Wardown Engineering in Dunstable, Beds they should be able to quote for this.
Tony

I'd be curious on the one-off cost for this job, or at least a ball-park.

Also want to see video of the part being bent. Maybe it's the nerd in me, but I find high-speed wire forming fascinating...

DanASM · Mar 16, 2020

Custom Wire Forming & Metal Fabrication Companies | Acme Wire Products

These are my guys for bending wire. They told me they can handle the .375" O.D. Wire/Rod that is the biggest stuff I need to bend.

Think baskets, shopping carts, etc.

I am sure you can find someone in the U.K. that does this. It is its own industry and they have machines built for this kind of work.

Try youtube for examples

fatguyslim · Mar 17, 2020

EPAIII said:
And without any tolerances on your drawing, no one will know just what accuracy you need. You have designed something, but have not given any thought as to just what those tolerances are, HAVE YOU?

There is an inverse relationship between tolerance and cost. The smaller the tolerance, the higher the cost. The larger the tolerance, the lower the cost.

Unless money is no object, then this is a basic part of design work.

PS: A reasonable inference from your drawing, as it is, would be all linear dimensions are +/-0.1mm and all angular dimensions are +/- 1 degree. But that may or may not work for your part. And do remember that tolerances on multiple dimensions and angles can all add to the maximums or all subtract to the minimums. So three linear dimensions with a 0.1mm tolerance can have an overall +0.3 or -0.3 mm difference. Either of these conditions would be considered to be "in tolerance".

I see what you mean and will try and work out my tolerances

fatguyslim · Mar 18, 2020

Is it possible to make this prototype using metal casting? Say if I get this 3d printed and then send the printed part to a casting company or someone in here who specialises in stainless steel casting. Will that work with something with such a thin diameter?

Peter from Holland · Mar 19, 2020

If I had to do a one or 2 off I would bend them with a torch and make some steel blocks with the right shape to bend then on
Start with the 43mm U shape Take a piece of stock 43 -7 = 36mm thick and use it as a simple jig Some radius at the end and bend the wire over heating it with a torch
Then a simple jig for each bend
Can be accurate

Peter

matt_isserstedt · Mar 19, 2020

I haven't totally thought thru all of the steps but I'm guessing a Diacro bender could make that fairly easily.

I'd budget about 6pcs worth of length of the virgin rod if it has to be perfect. There would be a little trial-and-error in setting up length stops or measurements to get it right, and possibly dealing with interferences as the part is progressively formed and its not a simple flat wire anymore.

Helpful to have access to a lathe to make the bender tooling pins.

AARONT · Mar 19, 2020

Milland said:
I'd be curious on the one-off cost for this job, or at least a ball-park.

Also want to see video of the part being bent. Maybe it's the nerd in me, but I find high-speed wire forming fascinating...

I agree. I could watch those auto bending videos all day.

Milland · Mar 19, 2020

AARONT said:
I agree. I could watch those auto bending videos all day.

Heh - someone needs to do a study on why this happens. Are bender fanatics easily hypnotized?

Milland · Mar 19, 2020

fatguyslim said:
Is it possible to make this prototype using metal casting? Say if I get this 3d printed and then send the printed part to a casting company or someone in here who specialises in stainless steel casting. Will that work with something with such a thin diameter?

This sounds really expensive relative to the basic shape and requirements. I think Peter has a good idea, but you might have to make some of the bending forms as "built up" segments, so you could separate them after the forming. This has an additional benefit of being able to shim the segments to correct length errors.

Peter from Holland · Mar 19, 2020

I immagened a seperate jig for every bend The jig has to possition or clamp that part of the product that is previous bend

peter

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