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  #1  
Old 10-20-2020, 01:18 PM
kjoiner kjoiner is offline
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Default 3D printed tooling for sheet metal bending

Hello,

I use my Stinger 1 mostly for cutting flat patterns in aluminum for prototyping small sheet metal parts. I've had a vise brake for many years along with a pan brake to form the parts. Frequently, I run into interference where the part hits the die. I found some sites where sheet metal shops are 3D printing tooling for press brakes and they work quite well - even for thicknesses up to 10ga steel. I decided to give it a try and printed a few small dies on my Prusa printer. They work quite well. I'm going to try to attach some photos to illustrate what I did. Two of the tools I created in Solid Edge, and one tool I downloaded and modified (the last one with the .03 radius). Basically, the mods include adding a top ledge to hang on the vise jaw and a pocket where I super glued a magnet so the tool will stick to the jaw.


Kyle
Attached Images
File Type: jpg 3D Printed Gooseneck Tooling 2.jpg (78.3 KB, 74 views)
File Type: jpg Vise Brake with Interference 2.jpg (36.2 KB, 75 views)
File Type: jpg Completed Bends 2.jpg (86.4 KB, 70 views)
File Type: jpg .03 Radius Gooseneck 2.jpg (53.5 KB, 71 views)
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Kyle Joiner
IPA LLC
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CAMaster Stinger 1 23
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  #2  
Old 10-21-2020, 07:17 AM
TimPa TimPa is offline
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very impressive design and application.

i am dumbfounded that 3d printer material has that type of strength!
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  #3  
Old 10-21-2020, 08:24 AM
kjoiner kjoiner is offline
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Hi Tim,
I was quite surprised as well and just had to try it. Here is a video that inspired me to try it out. The trick is in the settings used when slicing the part. I added extra perimeters which basically makes a thicker "skin" on the part and also increased the infill to 40%.

https://www.youtube.com/watch?v=wsxF...rt_radio=1&t=0

He does run one of the dies to failure. It was a gooseneck die like the one I made but the forces were higher. Tweaking the settings further would probably resolve that issue.

This video gets into forming sheet metal similar to stamping:
https://shane.engineer/blog/3d-print...et-metal-forms

Kyle
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Kyle Joiner
IPA LLC
www.thinkipa.com
Duluth, GA
CAMaster Stinger 1 23
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Vectric V Carve Pro
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Solid Edge 2020
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  #4  
Old 10-21-2020, 03:31 PM
Racegrafix Racegrafix is offline
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If you need a tougher material, just make mold of the 3d printed part, then there is some hard resin from smooth-on that will easily do it. Thats one of its applications.
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  #5  
Old 10-21-2020, 08:25 PM
DVE2000 DVE2000 is offline
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Thatís an awesome use model. Iíve had a 3D printer for a couple of months and absolutely love it. I may just get into sheet metal bending.

I actually created a bow sander for printing. Itís really strong, and you can tension the heck out of the sandpaper with it. Itís here, with the Fusion 360 design file: https://www.prusaprinters.org/prints...-with-f3d-file
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  #6  
Old 10-28-2020, 08:11 AM
kjoiner kjoiner is offline
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I've seen some very interesting applications for 3D printed injection molding tooling for short runs. It's amazing what you can do with plastic parts. One of the first 3D printed parts I ever did was a carousel type part that was for an automated pill dispenser. Picture something like the old school carousel slide projectors but with 31 compartments(for days of the month). This was back in 2001 and it was done on an FDM machine that cost $50,000. My Prusa printer can probably print better quality and is around $1200.

Kyle
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Kyle Joiner
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CAMaster Stinger 1 23
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  #7  
Old 10-28-2020, 08:13 AM
kjoiner kjoiner is offline
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Gary,

That bow sander is really cool! Thanks for posting the information and the files. I plan to download it and give it a try. By the way, if anyone is interested in the parts for the dies I made, I can try to post them on the forum.

Kyle
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Kyle Joiner
IPA LLC
www.thinkipa.com
Duluth, GA
CAMaster Stinger 1 23
FTC, Laser Cross Hair
Vectric V Carve Pro
Remote Handheld Keypad
Solid Edge 2020
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  #8  
Old 10-28-2020, 08:51 AM
kjoiner kjoiner is offline
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Here are STL files for the dies.

Kyle
Attached Files
File Type: stl Die, Vise Brake with Offset.stl (67.4 KB, 2 views)
File Type: stl Gooseneck Die, Vise Brake.stl (60.3 KB, 2 views)
File Type: stl Gooseneck+.03R.stl (196.7 KB, 2 views)
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Kyle Joiner
IPA LLC
www.thinkipa.com
Duluth, GA
CAMaster Stinger 1 23
FTC, Laser Cross Hair
Vectric V Carve Pro
Remote Handheld Keypad
Solid Edge 2020
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  #9  
Old 10-29-2020, 11:11 AM
DVE2000 DVE2000 is offline
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Thanks for the models. Yeah, I love my Prusa MK3S with MMU2S. It's pretty rock solid.
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