Using 3D Printing to Fabricate Harley Davidson Elements

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Our August 2019 Hacker of the Month, Chuck Taggart, resides in Southlake, Texas. Chuck started his skilled profession as a civil engineer, planning, designing and overseeing development and upkeep of constructing constructions and infrastructure, however moved into insurance coverage about 15 years in the past. He at present owns a big medical insurance company, Well being Reform Crew, primarily based in Grapevine, Texas.

Chuck started his journey into 3D printing after seeing a information phase on 3D printers about 5 years in the past. Quickly after, he determined to make the leap and buy his first 3D printer, a Zortrax M200. He additionally determined to get his kids concerned in 3D printing by having them design initiatives on their iPads, which he then printed out for them so they may improve their creativity past digital designs.

The filter cleaner Chuck designed and is currently applying for a patent.

The filter cleaner Chuck designed and is at present making use of for a patent.

Quickly after getting began, Chuck realized his designs had been a bit larger than the Zortrax might deal with, so he determined to upsize to a Modix 120X for actually big 3D printing capabilities.

Beginning with the Zortrax, Chuck primarily printed with ABS and used alcohol wiping and sanding to get a smoother end if he wanted it. However as soon as he moved as much as the Modix, he was in a position to actually begin printing with PETG and carbon-fiber infused NylonX. Chuck has used Autodesk123D Design for fairly a while, as he likes the comfort of taking his designs on the street and dealing on them on flights and in his (restricted) spare time.

“I additionally created a neat contraption that can begin my Inexperienced Egg charcoal smoker remotely from anyplace on the planet, in order that if I’m on my approach dwelling and wish to begin my Inexperienced Egg, I can do it from my iPhone.” You’ll be able to see a brief video clarification of the starter field right here: https://youtu.be/60zBdc9jnks

Chuck's remote Green Egg starter box.

Chuck’s distant Inexperienced Egg starter field.

However what’s the motivation behind Chuck’s 3D printing? “I simply have a head filled with concepts and I prefer to tinker. If I would like one thing to make my life simpler, then I take into consideration if I can 3D print it if it doesn’t exist. Or if I would like a component that I might simply make or that now not exists it’s cool to simply make one.”

The primary focus of Chuck’s designs heart on new creations and recreating elements that now not exist. “For instance, I created and have filed for a patent on a system that cleans pool cartridge filters in a few minutes versus the usual approach of hand spraying them.”

“ Additionally, final yr the daddy of a buddy of mine that’s into ’57 Ford Thunderbirds got here to me a few half for a supercharger (a cam ramp) that he says you may’t get anymore. The unique inventory half was made out of a sort of plastic and was not very huge, but it surely was fairly advanced. It took a little bit of time, however I used to be in a position to make this half for him, after which needed to make a bunch extra for his buddies. Now they’ve all of the elements they want.”

The Cam Ramp for the '57 Ford Thunderbird Chuck designed and 3D printed.

The Cam Ramp for the ’57 Ford Thunderbird Chuck designed and 3D printed.

However probably the most glamorous of all of Chuck’s initiatives are constituted of scratch – decrease fairings for his 2018 CVO Highway Glide Harley Davidson that merely didn’t exist earlier than he got here up with the thought to create them.  “These really assist defend me whereas driving throughout the nation on a motorbike by maintaining rain and rocks off my toes and decrease legs.”

Using the Modix 120X, Chuck was in a position to full the fairings in a single shot utilizing NylonX with out having to compromise the integrity of the print by combining smaller elements with glue or screws. (Excluding the clamp meeting to connect it to the body after all.) The design additionally incorporates Rockford Fosgate audio system, they usually have an incredible end that makes them appear to be they got here with the bike. The undertaking took over 4 months to finish, from idea to printing, to complete.

However what’s Chuck wanting ahead to with the way forward for 3D printing? “I’m certain the commonest factor individuals would reply with is pace, however there are some things I’d love. First off can be a major lower in price for actual steel printing. I’ve been following this very intently so when the fee will get down sufficient, I’m prepared for a steel printer. Second, can be customized coloring in real-time. For instance, identical to a shade printer runs off of perhaps 6 shade ink cartridges, it could be nice to see a 3D printer do that too.”

Chuck has additionally accomplished a motorcycle construct from scratch – the Daryl Dixon bike from The Strolling Useless, which you’ll be able to see movies of on his YouTube channel right here: https://www.youtube.com/consumer/CLTaggart/movies

Chuck’s subsequent undertaking is taking huge to the following stage; “I’m trying to 3D print a convertible prime for my Jeep Brute out of (in all probability) NylonX. I’ve it deliberate out and I’m within the design stage proper now.” We can’t wait to see the completed undertaking! If it appears to be like something like his Harley Davidson fairings, Chuck might must stop the insurance coverage enterprise and begin going into customized fabrication. We’ll you’ll want to share extra photos of Chuck’s progress with all his upcoming initiatives as quickly as there are updates!

Are you a 3D printing Hacker or know somebody that’s? We might like to share their story with the 3D printing neighborhood! Please e mail chris.morgan@matterhackers.com with info, and also you or your buddy could possibly be our featured Hacker of the Month.

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