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Firebrid: The Prius v Powered Hybrid Convertible

Discussion in 'Prius v Technical Discussion' started by Bill the Engineer, Jul 4, 2017.

  1. Bill the Engineer

    Bill the Engineer Senior Member

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    The 3D Printer has arrived! Time to make some 3D printed parts!

    20230804_182055.jpg
     
  2. vvillovv

    vvillovv Senior Member

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    How did the printer setup go? Is it user friendly, comparatively speaking? Some of um are well how do I put this, complicated just taking them out of the box.
     
  3. Bill the Engineer

    Bill the Engineer Senior Member

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    Waiting for a replacement cable to arrive. One of the cables was damaged (by me) during assembly. I'll provide an update as soon as it is running.
     
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  4. Bill the Engineer

    Bill the Engineer Senior Member

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    First part started on the 3D Printer!

    20230829_133812.jpg
     
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  5. Bill the Engineer

    Bill the Engineer Senior Member

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    The completed part. It is the prototype for the steering column adapter bracket to fit the Prius V steering column into the Firebird dash mount. If I like the way it fits, then I'll use this as the foundry pattern to have the part made from cast metal.

    20230830_112434.jpg
     
  6. ChapmanF

    ChapmanF Senior Member

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    Cast what kinda metal?

    I had an old Ford Bronco II where the steering column mount was some kinda pot-metal casting. I had a tendency to lean on the wheel when getting in and out. One day it just busted right off.

    A friend had the cast aluminum step fitting on her sailboat mast bust one day when things went a bit sideways while stepping the mast.

    She had a local machine shop copy the dimensions and mill one, which probably won't bust the same way (though I suppose that could mean it just tears up the deck instead).
     
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  7. Bill the Engineer

    Bill the Engineer Senior Member

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    Material TBD. Let's get there first!
     
  8. Bill the Engineer

    Bill the Engineer Senior Member

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    Second 3D printed part is a snap-fit adapter (white part) for the Firebird center A/C Duct (black part) to connect to the air hose going to the Prius V A/C unit. It snapped right on.

    20230831_185427.jpg

    20230831_185410.jpg
     
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  9. vvillovv

    vvillovv Senior Member

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    Looks like you have your printer all squared away. Your printed parts look great,already. Does it take much effort to spec out the designs?
     
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  10. Bill the Engineer

    Bill the Engineer Senior Member

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    I have the unfair advantage of having access to the Solidworks 3D CAD software, since I teach it at Del Tech. I was also a design and development engineer for over 40 years. Designing these parts is like zen therapy for me. I take whatever measurements I need on the car, then design the part, then dump it into the translation program for the 3D printer. I can usually turn out a new part that way about every 2 to 3 days.
     
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  11. vvillovv

    vvillovv Senior Member

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    Experience, having the right tools and knowing how to use those tools makes short work of what would otherwise be an exercise in frustration and redesign cycles..
     
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  12. Bill the Engineer

    Bill the Engineer Senior Member

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    I'm using every inch of the 3D printer bed. 20230907_172312.jpg
     
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  13. Bill the Engineer

    Bill the Engineer Senior Member

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    The latest three 3D printed parts snapped right together on the first try. (Adapter frame, right duct, left duct.) Onward!

    20230910_152450.jpg
    20230910_152513.jpg
     
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  14. Air_Boss

    Air_Boss Senior Member

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    Large scale 3DP parts!
     
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  15. Bill the Engineer

    Bill the Engineer Senior Member

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    Three steps in the 3D printing process.
    1. 3D CAD model creation.
    2. 3D Slicing program model.
    3. Final 3D printed part.
    (This is FUN! I'm having a blast doing this!)
    This part is the right a/c duct extension behind the glove box area.
    CAD Duct 5.JPG
    3D Slice Duct 5.jpg
    Finished Duct 5.jpg
     
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  16. Bill the Engineer

    Bill the Engineer Senior Member

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    First five parts fitted together.

    20230919_134731A.jpg
    20230919_134705.jpg
     

    Attached Files:

  17. Bill the Engineer

    Bill the Engineer Senior Member

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    The adapter is mounted on top of the a/c unit. Now on to the connecting ductwork.

    20231007_165012.jpg

    20231007_165024.jpg

    20231007_165055.jpg
     
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  18. mikefocke

    mikefocke Prius v Three 2012, Avalon 2011

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    Haven't owned a v for years but check back here to check on your progress. Impressive.
     
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  19. Bill the Engineer

    Bill the Engineer Senior Member

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    Before and after photos of the latest 3D Printed duct added to the Firebrid a/c system. The previous design was going to run into the wiper motor, thus the change. Step-by-step I'm getting closer to my goal...

    [​IMG]