Fully 3D Printed DIY electric car

General Discussion about electric bicycles.
808   10 mW

10 mW
Posts: 30
Joined: Nov 12 2020 9:17pm

Re: Fully 3D Printed DIY electric car

Post by 808 » Dec 02 2020 1:45pm

Balmorhea wrote:
Nov 14 2020 4:00am
3D printing is the hot glue gun of early 21st century
Balmo - I feed my habits and family by un-fuscrambling other people's wiring and mechanical "hotglu" jobs, every day sees more new stuff. If this keeps up (and I encourage it) I will be able to buy my adult child their own house.

Torchy   1 mW

1 mW
Posts: 11
Joined: Dec 04 2020 9:59am

Re: Fully 3D Printed DIY electric car

Post by Torchy » Dec 05 2020 12:52pm

I find this concept very interesting, 3d printing is a developing technology and I feel with the correct materials we will eventually be able to create very strong complex structures, we just need a bit of vision. Can anyone on this forum remember the 1950's Lotus Elite which was a very light fiberglass monocoque with no chassis and of course we have modern hyper-cars using moulded carbon-fiber sections held together with glue.

User avatar
The Toecutter   10 kW

10 kW
Posts: 943
Joined: Feb 08 2015 4:02pm

Re: Fully 3D Printed DIY electric car

Post by The Toecutter » Dec 05 2020 11:08pm

Torchy wrote:
Dec 05 2020 12:52pm
I find this concept very interesting, 3d printing is a developing technology and I feel with the correct materials we will eventually be able to create very strong complex structures, we just need a bit of vision.
There is a lot of potential there for sure. This will give home builders a relatively quick and relatively easy means to try new ideas that the major automakers do not dare touch.
Can anyone on this forum remember the 1950's Lotus Elite which was a very light fiberglass monocoque with no chassis
Yes. Almost no modern cars come close to it in terms of weight...
and of course we have modern hyper-cars using moulded carbon-fiber sections held together with glue.
...that weigh 4,000 lbs because they are loaded with extraneous luxury features to pad in more margins and "justify" the astronomical purchase price, and are also built to accommodate seating the morbidly obese Boobus Americanus, all at the expense of ultimate performance and efficiency... when steel body on steel frame sports cars from 5+ decades prior are half the weight.

So much wasted potential...

Torchy   1 mW

1 mW
Posts: 11
Joined: Dec 04 2020 9:59am

Re: Fully 3D Printed DIY electric car

Post by Torchy » Dec 06 2020 6:51am

Yes Toecutter but what a gift this new technology is for men in sheds.

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Dec 08 2020 7:32pm

There is a lot of potential there for sure. This will give home builders a relatively quick and relatively easy means to try new ideas that the major automakers do not dare touch.
I don't know if this is going to be quick and easy. :lol: :lol: :lol:
I have estimated the printing time around 400 to 500 hours that is about a month printing... :shock: Well with 2 bigger size printers time will be reduced to a week or so.

808   10 mW

10 mW
Posts: 30
Joined: Nov 12 2020 9:17pm

Re: Fully 3D Printed DIY electric car

Post by 808 » Dec 10 2020 8:05am

Looks cute. I hope it does well.
Last edited by 808 on Dec 13 2020 6:57pm, edited 1 time in total.

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Dec 12 2020 8:26am

Back to the topic:

I always promise myself that when designing a vehicle the first area is going to be the front steering/suspension geometry, but always I break my promise .... :(
So the front end knuckles have been ones of the lasts parts I have designed.
It was not in my mind to 3D print them and provably use CNC aluminium parts or similar.
But I was given the opportunity to test the nTopology platform for 7 days. Although it is a quite complex software due to its enormous capabilities, I was able to perform topology optimisation to the knuckles.
The people of nTopology liked the project and gave me some extra time to further work in them.

And here is what come out. It still may need some refinement but they will be something like this:
Attachments
Knuckle R V4 copia.png
Knuckle R V4 copia.png (498.04 KiB) Viewed 468 times

j bjork   10 kW

10 kW
Posts: 891
Joined: Aug 31 2018 3:01pm
Location: Linköping, Sweden

Re: Fully 3D Printed DIY electric car

Post by j bjork » Dec 12 2020 2:20pm

This looks interesting :thumb:
So the plan is to make a lot of small pieces and join them together?
How are they supposed to join together, only glue?

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Dec 16 2020 6:09am

j bjork wrote:
Dec 12 2020 2:20pm
This looks interesting :thumb:
So the plan is to make a lot of small pieces and join them together?
How are they supposed to join together, only glue?
Thank you Bjork.
Yes, lots of small parts joined.
I am working on a chemical welding product and procedure, in order to make the joints very strong.

999zip999   100 GW

100 GW
Posts: 9934
Joined: Jan 10 2010 1:40pm
Location: Dana Point So. Cal

Re: Fully 3D Printed DIY electric car

Post by 999zip999 » Dec 16 2020 1:05pm

I think you should put a little electric motor in those cute little cars with an RC remote control.

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Dec 20 2020 3:58am

More info about the DIY 3D PRINTED CAR. Today components, components and more components.
https://youtu.be/TADWhQN0rzM

[youtube]TADWhQN0rzM[/youtube]
Last edited by _GonZo_ on Dec 28 2020 4:50pm, edited 12 times in total.

goatman   100 MW

100 MW
Posts: 2656
Joined: Jun 23 2019 6:50pm
Location: Surrey, B.C.

Re: Fully 3D Printed DIY electric car

Post by goatman » Dec 20 2020 12:12pm

a new youtube to follow :thumb:
ive been waiting for a reason to get a 3-d printer
how big of a printer will i need
any recommendation for one?

markz   100 GW

100 GW
Posts: 12169
Joined: Jan 09 2014 11:38pm
Location: Alberta Canada

Re: Fully 3D Printed DIY electric car

Post by markz » Dec 20 2020 8:55pm

How much money you willing to spend?
goatman wrote:
Dec 20 2020 12:12pm
a new youtube to follow :thumb:
ive been waiting for a reason to get a 3-d printer
how big of a printer will i need
any recommendation for one?

goatman   100 MW

100 MW
Posts: 2656
Joined: Jun 23 2019 6:50pm
Location: Surrey, B.C.

Re: Fully 3D Printed DIY electric car

Post by goatman » Dec 20 2020 9:26pm

its not what im willing to spend

i like getting used stuff that is known to be reliable
parts that are readily available and reasonable
kind of like a 350 chev instead of a Tesla

User avatar
Dauntless   100 GW

100 GW
Posts: 10841
Joined: May 29 2010 1:49am
Location: Coordinates: 33°52′48″N 117°55′43″W

Re: Fully 3D Printed DIY electric car

Post by Dauntless » Dec 21 2020 1:13am

www.markforged.com/

[youtube]UdiwBiw5dyo[/youtube]
Any sufficiently advanced technology is INDISTINGUISHABLE FROM MAGIC!
- Arthur C. Clarke

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Dec 22 2020 6:05am

999zip999 wrote:
Dec 16 2020 1:05pm
I think you should put a little electric motor in those cute little cars with an RC remote control.
That will be cool.
You are really welcome to modify it and add all the RC things into it.
You can download the STL files from here: https://www.prusaprinters.org/prints/47678
And you can download on any format, or modify the 3D design here: https://cad.onshape.com/documents/e8885 ... 454fb6d9f9

Please let me know if you do so.

User avatar
Dauntless   100 GW

100 GW
Posts: 10841
Joined: May 29 2010 1:49am
Location: Coordinates: 33°52′48″N 117°55′43″W

Re: Fully 3D Printed DIY electric car

Post by Dauntless » Dec 25 2020 4:48pm

Here is just an example of the future of 3D printing being largerprinters, not stitching smaller parts together. Some 10 years ago a college built a car out of something like particle board and the whole thing collapsed under its' own weight before it was finished. Good thing they weren't driving it. Your glued together parts are going to be a question mark.

[youtube]XHSYEH133HA[/youtube]
Any sufficiently advanced technology is INDISTINGUISHABLE FROM MAGIC!
- Arthur C. Clarke

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Dec 28 2020 5:20pm

Buildings have been always made using additive manufacturing processes. The only difference with that, is that a machine is doing the job it instead of men.

Yes it will be easier and faster to print it in a few parts using a huge printer, but:
This is an OpenSource project so if I use custom machines or not easy available machinery it will not be OpenSource anymore...
And more important, I do not have a huge 3D printer or the resources to access to one.
I am working on a chemical welding product and procedure, in order to make the joints very strong. Far stronger than the parts themselves; If you are worried about that...

Addy   100 W

100 W
Posts: 260
Joined: Aug 11 2017 11:15am
Location: BC, Canada

Re: Fully 3D Printed DIY electric car

Post by Addy » Dec 28 2020 6:51pm

_GonZo_ wrote:
Dec 28 2020 5:20pm
I am working on a chemical welding product and procedure, in order to make the joints very strong. Far stronger than the parts themselves; If you are worried about that...
This part of your project will be quite interesting.

If you were using ABS plastic, acetone would be great for welding the parts together. For a 3D printed quadcopter frame I mixed acetone with ABS to make a kind of solvent slurry which then could be used to glue parts together.

Image

This resulted in joints that were stronger than the pieces they were connecting. Unfortunately, ABS is not an easy material to print without warping, unless you have a heated print chamber.

These days I am mostly printing with PETG plastic and it would be nice to have a glue like I had with ABS, though I haven't researched this topic much.

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Jan 04 2021 6:56am

Addy wrote:
Dec 28 2020 6:51pm
This part of your project will be quite interesting.

If you were using ABS plastic, acetone would be great for welding the parts together. For a 3D printed quadcopter frame I mixed acetone with ABS to make a kind of solvent slurry which then could be used to glue parts together.

This resulted in joints that were stronger than the pieces they were connecting. Unfortunately, ABS is not an easy material to print without warping, unless you have a heated print chamber.

These days I am mostly printing with PETG plastic and it would be nice to have a glue like I had with ABS, though I haven't researched this topic much.
That is the idea; To use a similar chemical welding as it is used for ABS or PVC.
I have good news, after dusting off my organic chemical knowledge, I think have found the right mix of solvents and fillers to create a similar product to be used in PLA (It looks like it can works as well on PETG). It still needs some refinement in order to get the right proportions of solvents/fillers, and the right fillers in order to get the right joint elasticity. But it actually works, and the first tests looks very promising.

More info in following days.

julesos   10 µW

10 µW
Posts: 6
Joined: Aug 03 2020 9:41pm

Re: Fully 3D Printed DIY electric car

Post by julesos » Jan 20 2021 11:58pm

Great project! — I’ll be following your YouTube journey closely. I’m also working on a micro EV project, using a Greenspeed Glyde as the base.

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Jan 25 2021 7:13am

I managed to design a glue for PLA plastic that actually creates stronger bondings than epoxy ones.
More than a glue is a chemical welding product. It is made with a solvent (Dichloromethane) PLA as filler.
It really works well in PLA, PLA+ and PETG but need some more test in this last one.
I am now working in the proportions (Filler/Solvent) in order to get the best results and easy to use.
Made a vido comparing different bonding systems:

[youtube]5LqmyYqS6-k[/youtube]

User avatar
spinningmagnets   100 GW

100 GW
Posts: 11854
Joined: Dec 21 2007 10:27pm
Location: Ft Riley, NE Kansas

Re: Fully 3D Printed DIY electric car

Post by spinningmagnets » Jan 25 2021 11:58am

A good PLA glue is a very useful thing, thanks for posting this...

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Feb 01 2021 7:04am

First parts just come out of the printer (door parts+), all looks good so far.
Next step chemical welding.
Attachments
2021-01-27 19.51.31.jpg
2021-01-27 19.51.31.jpg (1.98 MiB) Viewed 84 times
2021-01-27 19.57.13.jpg
2021-01-27 19.57.13.jpg (2.04 MiB) Viewed 84 times
2021-01-27 19.59.37.jpg
2021-01-27 19.59.37.jpg (2.09 MiB) Viewed 84 times

User avatar
_GonZo_   10 W

10 W
Posts: 94
Joined: Jan 18 2010 5:47pm
Location: Spain

Re: Fully 3D Printed DIY electric car

Post by _GonZo_ » Feb 03 2021 5:39am

Here is a picture of one of the parts in a section cut, so you can see how they are inside.
As you can see the parts are almost hollow (See picture) with an internal gyroid estructure. The walls of the parts varies from around 1.2mm to 3.9mm and the infill from 9% to 15% of the volume, depending on the stress of the area.
So parts are quite light and strong.
The panels that compose the unibody and door have a thickness from 10mm to 20mm depending on how much stress that area has to handle.
Attachments
2021-02-02 20.01.43.jpg
2021-02-02 20.01.43.jpg (2.59 MiB) Viewed 67 times

Post Reply