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3D print projects. 

​​Custom parts, hard to find parts, replacement parts and new designs.
A lot of us are thinking more about how we can reduce our waste, and repairing, rather than throwing away should be everyone's goal today. PLA is Bio-degradable and environmentally friendly (For the technical detail see here). Some brands are even made from recycled material. So, if you have a broken part that you want to repair or replace get in touch and we'll see what we can do. You will be helping the planet at the same time.

The original side panel.

The first copy just off the printer after more than 30 hours.

The original along side the recreated panel. The side bulge and switch openings were never required.

The new design being offered up to the new tank.

The original side panel from the inside

This big twist on the panel was very difficult to reproduce with no reference plane.

The side panel curved in all planes!

The first copy inside showing the integrated supports to be removed after printing

One of the design trials just finished

One of the many design iterations just coming off of the printer after 36 hours!

Custom panels for a very special Suzuki Katana.
Another interesting project from my regular customer Wren Classics - www.wrenclassics.com. This time a bike project rather than one for the cars. A customer of theirs was having them make a very customised version of a classic 1986 Suzuki Katana. One of the major mods was a new fuel tank shape and that meant the original side panels needed to be replaced. These original panels are very hard to get and very expensive; especially as they would need several waste panels to try new designs. They asked me to first create an identical copy of the original panel and then create new printed designs as it evolved before finally 3D printing the panels that will be fitted to the completed bike.

The panels have some very difficult curves and twists in them that made the 3D CAD work very difficult, but after many hours and multiple prints I arrived at a near perfect replica of the original panel. Within minutes of delivering the panel to Wren they were attacking it with an angle grinder! Several new designs were tried with each print taking approximately 36 hours! However, we got there in the end and both the engineers at Wren and their customer were very happy with the result.

The final model with new bodywork all painted in the real colours and sponsor logos

Final CAD rendering of the full scale bodywork.

Original body work

The original rear deck being measured.

Original rear deck top view

3D printed engine cowl in carbon fibre lookalike black filament.

3D printed rear deck

The completed rear deck assembly

New bodywork for a vintage racing car!
A very interesting, but very different project from a regular customer - Wren Classics. An historic racer and Aston Martin restorer - www.wrenclassics.com.
Steve Farthing the owner, contacted me to produce some scaled body work from his Lola T332 Formula 5000 for a 1/16th scale model he was having created by a specialist company in Australia. They could handle the chassis and some parts of the body, but not those parts very specific to Steve.
I needed to recreate full size body panels in 3D CAD before scaling and finally 3D printing. Very careful measurements, LOTs of photos and many hours of CAD design later, I was able to faithfully reproduce the whole backend deck and engine cowl in a carbon fibre lookalike black filament. The parts were sent off to the maker in Australia and came back looking amazing!


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Saving a cherished MK 3 Zodiac restoration.
A recent project that was probably the most technically challenging that TFW has undertaken to date.
My customer is doing a full restoration on his 1965 MK3 and has scoured the world looking for replacements for the front quarter light window rubbers, with no luck at all, although not short on undelivered promises! Apparently, window rubbers for MK1, 2 and 4 are commonly available, but the MK3 is a rarer beast. He came to me with a carrier bag of completely rotten rubbers on which most of the profile had simply gone. After months of 3D CAD work I recreated as close as I can the original profile. Although this could be improved if I ever got to see an original! Once the CAD drawings were complete I was able to give the customer two options: The first is to 3D print the rubbers in a very flexible TPU polymer, and the second is to 3D print with a solid polymer and create a near original to mould new rubbers in Silicone rubber. There were price constraints on this project and the customer opted for the 3D printed set. The flexible printed versions are complete and now installed and they look pretty good. The customer is as happy as he can be given his options. Not only do the printed rubbers look good he tells me that even at 50mph there is no more wind noise than the originals had and so far they don’t leak. These really got him out of a big hole with his project.
As an option I created a sample mould of one corner and created a nice black rubber piece and that turned out very well indeed, but the upfront cost was a little steep at this point. There is an option to upgrade to the moulded ones in the future, but at the moment the printed ones are working fine and as it’s a bit of a workup to change the rubbers once installed they will probably stay there!
If you are working on a restoration or simply a repair to a classic car, I can also recreate other parts such as broken light lenses etc. as long as I have a drawing or the broken sample or even the opposite hand I can usually reverse engineer the part and either 3D print the piece or create a mould.
Please contact me if I can be of service to you on your own project or maybe you are a member of a car club that would be interested.

Original gear rear

New gear rear

Original gear front

New gear showing pressed in steel drive gear

​3D printing saves the day in this high mechanical stress environment.
At first this looked like an impossible task for the client – A broken gear in a shredder.
Shredder gear trains have massive loads put on them when people overload the shredder and if a single tooth is damaged the machine is usually written off.
With the broken gear in hand, I was able to reproduce an exact copy in a high strength industrial polymer. This one had the addition of a metal driving gear embedded in the surface of the original. A matching recess was created as part of the CAD model and the gear fitted perfectly in the final 3D printed part. The new gear was fitted and the shredder returned to its former glory…

The speedo assembly

The original broken gear

The new gear in place

The new nylon printed gear showing the 8 deg helix angle

Repair to a classic Mercedes VDO speedometer.
The client came to be after trying, and failing, even from the largest parts suppliers in Germany, to find a replacement trip drive cog for the VDO speedo in his Cosworth powered Mercedes.
The original cog had split on the collar and would not grip the shaft. I was able to reverse engineer the tiny 11mm dia gear and reproduce the 8 degree helix angle to ensure smooth operation. It is printed in a tough Nylon polymer. Tests showed that the trip is now working perfectly.
Reverse engineering and either 3D printing and / moulding replacement parts is great way to get that classic car back on the road.

Left side rear old and new

Right side rear old and new

Left side front old and new

Left side rear old and new

Reverse engineering and 3D printing are formidable tools in the battle to reduce waste.
These old window awning awning covers were cracked, ugly and obsolete making the whole awning ready for the scrap heap.
Even in their particularly sorry state TFW was able to reverse engineer the original end covers and produce new ones in a tough, flexible polymer that should be able to withstand the elements for many years.
If you have an obsolete part you need to replace, be it from a domestic appliance or a classic car part let me know. There is often a solution with 3D printing

The original part

Comparing the old and the new from the rear

Comparing the old and the new from the front

Replace or repair? £125 or £25?
This was the choice I was able to offer a client this week when he faced the challenge of fixing 12 badly aged window handle covers. Badly cracked and in desperate need of replacing. The choices were replace with new, at a cost of over £125 or for TFW to reverse engineer and improve the design. I was able to 3D print new covers at a cost of just £25. The new covers fitted perfectly and were an easy fix compared to the replacement option.
Do you have a similar project that you can't find a solution for? Reverse engineering and 3D printing can often be a good and cost effective solution.

Soda stream lever arm

Side view

3D printed part saves a man's Whisky and soda!
A recent repair brought to the shop was this operating lever arm for an old soda stream machine. A part not available anymore. So rather than consign it to the landfill, I was able to reprint the arm in a PLA polymer. The arm fitted perfectly and restored the machine to it's former glory.
Before you through out that broken item, give a call and let's see if we can save it

The "Digestive issue"

The cover

The solution

Works for cream crackers as well!

A polymer test piece turns into a fun and practical object.
When ever a new 3D print polymer comes along it's important to understand its properties and applications so that I can recommend the correct material to clients. Rather than just run test pieces it's always better to make something "real". I don't know about you, but I hate soft digestives or Hob Nobs...
So a cover was designed that fitted over the top of the open packets with a tight rubber seal to keep them fresh. For fun I created a square one for cream crackers! The polymer was a TPU flexible material ideally suited to this type of application. Let me know if you have a "second bottle of wine" idea that you would like to see in the flesh. You never know, your next mad idea could be the next best seller!

DB7 Super charger bypass tool

Aston Martin restorer and vintage racer Wren Classics, needed urgent help with this special setting tool.
Wren classics contacted TFW with an urgent need to design and manufacture a special piece of set up tooling. This DB7 Super charger bypass tool is a specialized piece of kit that is one of those things you don't need very often, but when you do it has to be right. A drawing was made by Wren classics and sent over via email. I made a visit to make sure that I understood the sketch perfectly and to get an idea of the tolerances required. Less than 24 hours later a prototype was delivered and tested. After confirming all was ok another 4 were made "just in case". Other than the critical dimensions and functionality, one concern in a busy restoration shop is durability. It had to be able to "bounce" if dropped! This piece was made in PETG, a dimensionally stable, strong and semi flexible polymer. The cost of custom tooling like this may be less than you imagine. Contact me to find out more.

Vacuum hose and 12mm hose to be connected

Flexible connector in place

Flexible Polymer saves the day for a Plumber
The easiest way to clear an air lock in house plumbing is to attach a vacuum cleaner to the blocked pipework via a tap. The problem is how to connect your vacuum cleaner hose to a tap connector?
You could use lots of duct tape, but would it be water proof? The answer was to 3D print an adaptor in strong, flexible polymer. The adaptor created a water and vacuum tight seal between the 34mm vacuum hose and the 13mm tap hose. The vacuum sucks the air out of the system until water runs freely. No mess, no need to access the loft space. This polymer has a hardness of 40D on the Shore hardness scale so is ideal for applications that require high strength while still offering flexibility.

Flexible filament

3D CAD design reverse engineered from the original design

Bracket in place

Final bracket in Nylon and PETG

​Custom bracket for a Datsun 240z restoration.
A popular upgrade for 240z restorers is to modify the car for modern halogen headlights. However, the sensible course is to switch the lights through a relay rather than risk running all the current through the original interior switch wiring. The downside is it needs a relay mount. The customer in this case had searched in vain on the internet for a suitable bracket, but did find one that was close to what he needed on the web site  www.thingyverse.com. This site has thousands of free models to 3D print, but you’ll be lucky if they meet your exact requirements. In this case, the customer sent me the original thingyverse file to print, but asked me to reverse engineer the bracket to suit his exact need. The result was a reimagined bracket, printed in a couple of different materials and colours, all within 24 hours. Happy customer.
If you are undertaking this or a similar restoration project and need a special part, contact me at: www.thefusionworkshop.co.uk.

The final design

Print in place tensioner

The slots take up the slack

Print in place tensioner in use

The first printed prototype

The gold one!

3D printing for engineering prototypes.
Whether it’s for a one off, impossible to find spare part, a prototype for a production run, or a proof-of-concept model for marketing, 3D printing is the most cost-effective way to get the job done.
While photo realistic computer renderings get an idea into a form a customer can understand, a prototype model gives them something they can hold, and that means a great deal, especially to customers that are not from an engineering background.
Take this idea for example: It cam from a regular business traveler that was fed up with unknotting his ear buds as he settled in for a flight. He had a very vague idea that the cables should wrap around something, but that was as far as it went. He brough the idea to me and I went to work creating various designs. Photo renderings narrowed it down, but it wasn’t until we both held the model that the good, and the bad points came to light. Coping with different lengths of wire or just the tightness of winding caused issues with slack cables. A few ideas were tried, some more complicated than others. Just two more iterations followed, each only taking an hour or two to print and we had a working product with a smart, simple, cheap method of changing the effective winding length. Now in this case it was a one off for personal use, but it could just have easily been the beginning of a great commercial product. We could even try different colours and textures, including a blingy gold one…
So, before you give up on your idea, come and talk to me at The Fusion Workshop. www.thefusionworkshop.com

Original gear train

Original pinion. The original spacer has melted away

The power of advanced 3D printing saves a tool from the scrap heap
TFW is part of a Facebook group called the Blandford repair café and have just finished an interesting repair. It was a multi tool oscillating sander where the motor went round but the pad didn’t vibrate. I found that the original gear train had melted because of a seized bearing and that meant the bevel gears didn’t mesh. I couldn’t be certain of the various parameters of the original gears to replace just the damaged part, so drew up a new set, complete with a new spacer, in 3D CAD. (Autocad Fusion 360). These were printed in a super tough nylon filament (Nylon 230 by Taulman). Runs like a champ now!  Running-in tests showed no discernible wear after 30 mins continuous  use. Only time will tell, but it opens up a whole new world of possibilities!

New 3D printed gear train.

Design in Fusion 360

Hot brush with replacement comb inserts

Design in Fusion 360 CAD

Another product saved from landfill.
A recent project that not only saved this hot brush from being thrown away when the comb inserts disintegrated, but I was able to improve the design to stop it happening again. Rather than take the current design as is, I took the opportunity to improve the design to give more structural integrity to prevent the combs breaking in the future.
The combs were recreated in 3D CAD (Fusion 360) and then printed in industrial plastic. The finished combs were then annealed at 110 Deg C for 35 minutes to further strengthen them and push the temperature limits to over 95 Deg C. The hot brush core reaches a maximum temperature of 93 Deg C. These inserts have been in place now for several weeks and still looking good.

"Minion"

A single 0.5 W spherical led

Good ergonomics

"Dougal"

Multiple design iterations

0.85mm slot and 1.4mm wire holes.

Two 0.5 W Spherical leds

Room on the back for a name or a logo

Beautiful and functional product prototypes aren’t just for big-budget design firms anymore.
3D printing technology puts great-looking prototypes and quick and cheap design iterations, within reach for practically any design sector. Be that a hobbyist or a professional. If you’re an inventor, or just have a great idea for a product, your prototypes should look and feel like the final product.
This little torch was formed from an idea for a small bedside table light for those nocturnal wanderings....
The concept was that it should be as small as possible built around a PP3 battery, but not so small as to be unergonomic for those who may have difficulty gripping or operating a tiny switch. It needed to stand on its own, could lie down if required and without rolling off the table. I came up with a couple of designs - The white one we nicknamed "Minion" and the other "Dougal"(for those that remember the magic roundabout..) It sort of looked like him when lying down. While the CAD model looked great and was really close it wasn't until the first print came off and it could be handled that some minor issues came to light. Those were corrected until it "felt right" I was also able to try several different front pieces, slide switches and colours. Printing new pieces was less than 30 mins and soon the final two designs came to life.
Dimensions can be very tightly controlled. The slot for the slide switch was adjusted by 0.05mm for a perfect sliding fit. The two holes showing are 1.4mm dia and conceal the wires. 

"A place for everything, everything in its place"
Benjamin Franklin was absolutely right when he said this, and a local gardener had the same idea. She wanted to get the tool shed all neat and tidy and just couldn't find tool holders that fitted her smaller tools. So I was asked to design these four different holders for the more difficult tools. Each one was tailored to the tool and one was made in a different colour so it was quickly obvious which tool went where. Good tools are expensive and deserve to be stored correctly so if you have tools that need "their own place" then let me know. Then you too will "Have a place for everything"

Printed Heater dial adaptors for a Converted VW T5 camper van.
The customer for these heater adaptors was struggling to find original replacements, but managed to find an STL file on the internet. Only problem, he doesn't have a 3D printer. So he asked me if I could print a set for him. The problem with STL files are that they are not very editable as far as accurate dimensions are concerned. To make sure they are tight enough, but not too tight meant I needed to create a few samples for him to try. A few samples later and we had a good fit. I made the prototypes in standard PLA to keep the cost down and once we had a good model I made a final print in an industrial plastic that can withstand the possibly high temperatures behind the dashboard. I guess I could say he was "a happy camper"

The original pump handle recreated in 3D CAD

The finished replacement handle.

Replacement air bed pump handle.
Another one of those jobs that before 3D printers would have been consigned to the scrap heap. However; in this case the broken handle was recreated in Fusion 360 and printed in a super tough PLA. At the same time I was able to improve the original design to add strengthening fillets where they needed to be and increased the density of the handle fill in weak ares. It should last longer this time. The thread in the main body was a challenge because the type was unknown. I created very small samples that printed quickly and arrived at the conclusion that it was an 1 1/8" thread (The pump was bought in the USA)  from there it was simply a case of reproducing that on the final CAD version.

This is where it all starts. An idea..

Turned into a technical drawing

​Motorcycle handle bar spacer.
This project was for a client who needed a special spacer for his motorcycle. He sent me a sketch of what he wanted, 20 minutes later I sent back a drawing and a rendering for approval and sign off. I printed his spacers that afternoon and dispatched the same day.

A photo realistic rendering ready for approval.

Spacers ready to print

Samples of the old parts

Ready to print

Drawn and rendered in Fusion 360

Window mechanism washers for an old Datsun 240Z under going restoration.
These washers were unobtainable and the client asked me if I could reproduce them from some old samples. The samples duly arrived and although they were in a pretty bad state I was able to recreate them in CAD. The original material had hardened over the years, but they had to be strong but flexible. I chose Nylon for these as that has the mechanical strength and flexibility that I required. I was able to utilise another one of the marvellous properties of 3D printing; to change the percentage of the internal "fill" of the part. I sent the client a variety of samples from 20% (more flex, but not as much strength, 50% (more strength, less flex), and 70% (high strength with a little flex). The client chose the 70% fill after some trials and I was able to ship out 12 of the two different sizes the next day. A spacer bush was also recreated at the same time. This piece in a high strength Nylon.

Replacement dishwasher runner

"Print in place" axle

Rendered CAD model

Replacement wheels for a dishwasher.
I have to admit that this was a "Homer" as we say. I.E a job for myself. After a long time struggling with missing wheels in our dishwasher my wife finally persuaded me to do something about it.
The work flow was the same as the other projects: Start with a sample, draw in Fusion 360, then print. This time I had two other problems to solve. The first was the axle. I could have made a separate axle, but that would have made it more complex to assemble and I would have to design fastenings to hold it in place. A dishwasher is not the kindest place for metal parts either. So I designed this with another innovation that only 3D printing can offer - "Print in place" rotation axles. You can see in the section drawing that the axle (in blue) is in the model already. With the correct clearances applied the axle and body will be printed so that after printing the axle will rotate inside the body. The second problem was the environment inside the dishwasher - wet, obviously, but also high temperatures of 80 DegC. I chose a material that can be annealed after printing in a  low temperature oven and then is resistant to distortion up to and beyond 90 DegC. The wheels have been in place for 6 months and are still running perfectly. This industrial grade plastic is also ideal for hard wearing items like gear wheels or projects that need a higher shear strength. And yes, I could have used grey...

Bottle adaptor for plant watering and feeding

* Adaptor set available to purchase. Contact us for more details.

Milk bottle adaptor.
No, it's not a system for feeding orphan lambs, but it could be. It's actually a set of adaptors that turn a standard 1 or 2 Ltr milk bottle into a controlled watering / feeding system. Gardeners will appreciate that a lot of plants, especially vegetables like courgette, tomato and cucumber don't like having either their leaves or the stem wet. Gardeners have many solutions such as an inverted flower pot next to the plant, but they tend to be large, don't hold much water and deliver the water too quickly, so disturbing the roots. This system puts the water 80mm down, right next to the root. You can choose between a fast or slow delivery depending on the plant and the soil. You simply cut the end off of the milk bottle, screw on the adaptor cap and select a nozzle. Stick the whole assembly in the ground and leave it there. Simply fill the bottle up from the open end and walk away. I think this is a great idea - I use it myself and the results are terrific.
Printed in standard PLA. Note the embossed writing on the nozzles. Another great feature with 3D printing that would otherwise need an expensive mould.
​You can print virtually any standard thread, but this was a non standard size that was easily created in Fusion 360.

Complex enclosure and mount for an oil level sensor
This is a Fusion Workshop project that combines a small IOT electronic module with a complex enclose and mount to go inside and on top of a large heating oil tank.
The mount design was complicated by the fact that it had to go through the skin of the tank which is curved. There is a "tunnel" piece that goes through the skin at an angle that puts the sensor enclosure parallel to the surface of the oil inside the tank. The top circular part of the enclosure you can see in the picture contains the main control PCB and the radio to connect to a base station. The design allows the top section of the enclosure to be removed leaving the sensor module inside the tank. There a large 33mm thread created in the angled tunnel piece to attach the main enclosure. In the main enclosure there is a completely printed battery holder and retaining clips for the PCB. There would have been no way to create such a complex structure without 3D printing. Certainly there would be no "off the shelf" solution.

Tail stock assembly for a Laser rotary chuck.
This project is a great example of how Laser cutting and 3D printing can be combined to create unique products.
The tail stock assembly has 5 different parts all 3D printed in PLA. The thumb wheel at the bottom is used to raise and lower the twin wheel support assembly. The slideway and a square nut on the leadscrew had to be printed with very tight tolerance to ensure smooth motion.
With full control of the density of the internal fill layer, areas for screw threads can be made very strong and capable of being tapped with standard threading tools, while leaving the rest of the project with a lighter fill to print quicker and use less material.

1/2" BSP nut

33mm Nut and bolt

3D printed nuts and bolts.
Printing impossible to find hardware is a great way to get parts created or repaired. Here are a couple of jobs that came through the workshop recently.
The first was for a client who had a broken light fitting and could not find a replacement nut. Rather than throwing away the fitting and all the cost and hassle that goes with that, it was a simple job to recreate the broken part in 3D CAD and print a replacement. Job done, happy customer.
Another job was for a custom electronics enclosure and needed an M33 Nut and bolt. Again, created in 3D CAD and printed.