Custom motorsports components with EinScan-Pro & UP Box+
With the 2016 year winding down, we wanted to take a moment to share a cool project we have been working on here at MakerTree 3D. This project that has utilized a couple of the more popular products we've seen this year, which include the EinScan-Pro 3D scanner from Shining 3D and the UP Box+ 3D printer from Tiertime.
This project's focus was on a 2011 Yamaha Stryker motorcycle. This bike has already been customized in numerous areas, but has a hint of an apocalyptic theming with the chromed Zombie Pegs, and custom designed skull/ gasmask gauge background.
What was on the agenda for this newest customization, was going to be a new custom themed gauge cluster bezel/ cover. The original Yamaha bezel cover worked, but continuing the apocalyptic theming for this component, would also allow us an opportunity to also add a small visor that would extend slightly higher than the original bezel which had no visor shield extension.
Once the original bezel was removed, 3D scanning to capture the dimensions of the bezel would assist us with a base for us to build our design from. The EinScan-Pro 3D scanner was used for it's accuracy and ease of use. With the OEM bezel being black on one side and shiny chrome looking on the other side, a scan spray was used to provide a light color, non-shiny surface which is ideal for 3D scanners to capture data from. We used both Fixed Autoscan mode with the turntable, and finished off the scan with a few single scans done with Fixed Freescan mode to capture a couple of hard to see areas.
Now with a watertight digital model of the OEM gauge cluster bezel from the EinScan-Pro, we were able to move this data into the free application, MeshMixer from AutoDesk. With the scanned model in MeshMixer, we were able to import other model components that we found for download on Thingiverse. This consisted of a gas mask portion and a skull portion that we were able to position all of the components together into an orientation we were pleased with. MeshMixer's sculpting tools are simple, yet powerful enough to allow for a great deal of refinement through adding, removing, blending, smoothing and carving of the models imported.
With the digital sculpting completed, it was time to get the model in for 3D printing. With many different model 3D printers to choose for use at MakerTree 3D, we selected the UP Box+ for it's large build volume, quality of it's print results (especially with ABS)as well as the powerful Smart Supports used by the UP printers which give some of the cleanest print results we've seen where parts contact the support structures. The material selected would be the UP Fila ABS due to it's inherent high temperature and impact resistance, and would be 3D printed at 0.2mm layer heights.
The UP Box+ printer reproduced the large ABS part perfectly and only took about 15 minutes to remove all of the support structures from the part. A first test fitment showed the part fit exactly as intended and now was time to begin hand sanding. Starting with 220 grit, then to 320 and ending with 600 grit sandpaper, the print lines and any other areas were sanded smooth. Using a filler Primer from Lowes, the part was sprayed, sanded again and some filler material used to achieve some final contours, then another coat of filler primer and the final sanding.
Finally, with a nicely refined, and sanded smooth model, we were now ready to move to paint. We chose the Rust-Oleum Carbon Mist paint from Lowes, which has an amazing color and shine for this part. Once we had multiple final coats applied to help endure it's life on the road, the hardware was reinstalled and the new custom gauge bezel cover was complete.
We have planned ahead and created in the CAD model, the holes to run LEDs into the eyes, but before doing so we'll work on a light diffuser design and filament that we'd like to use for this purpose. This will be saved for a separate project/ blog post at a later time. :-)
Happy Holidays from MakerTree 3D, and we wish you all an amazing and prosperous 2017!
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