While this piece prints, I'm creating the spacer to go into the near side by the clamp and the end that will attach to the broom. The fun part of all of this is that I don't know if it's going to work. The scary part of all of this is I have no idea if it's going to work.
During the printing process, I'm realizing that the holes for the bolts are too big, watching the printer struggle to make round holes that size in the middle of a print. For future reference, I'll be modifying this to adapt to smaller bolts. I wanted them to be big so that there would be a strong connection, but the ABS material is solid itself, making the need for reinforced bolt sizes a bit irrelevant.
Also, there is a little bit too much "curling", when the plastic peels up off of the glass. Dang it John, stop being so cheap with the glue!!!! Nobody said that this was going to be a simple learning process, so fortunately I have a low stress environment in which I can just tinker and learn. Wait- wouldn't it be nice if students had the opportunity to do the same? Nah, this is totally different than a classroom setting.......
As the piece is printing, I'm actually pretty happy with it. It's flat on the top and bottom and has some play along the sides, which will allow for adjustment and wiggle. This is turning out to be pretty daggum cool.
6/8/14 (7:29 pm)
Update: I'm stuck. For some reason, the code for the model is skipping about a dozen layers, creating a pile of filament and not printing the middle portion of the piece. I've gone back, filled gaps, tried a few different renderings, but it isn't working for me. If you know anything about Google Sketchup and 3D modeling, I would really appreciate a hand. Click here to access the file I'm working on. I've given up for the evening, but will come back to face my demons tomorrow.
6/9/2014 (9:25 pm and counting)
Update 2: I'm (maybe) unstuck. Thanks to a kind fella on the Twitters who knows a thing or two about Sketchup, I've gone back and repaired my non-solid solid figure. Yeah, oops. Ever been that kid who forgot to do that important step to solving the problem because you already knew the answer? Meh, me neither...
The reason that each piece is being printed out separately is because of the travel time it would take to print all pieces out if they were on the same print. If you think about it, the Airwolf prints one later at a time, so it would be traveling between each piece every time a layer shifts. YUCK.
In reflection, this would be a great lesson for kids to recreate. By default, I was measuring, drawing, relating back to my sketches and math, making modifications, accounting for flexibility, a small margin of error, and modeling a ton. Hey - that's what Common Corgi wants us to do! Not only that, but I made multiple modifications to the design and regenerating the design and seeing that something wasn't right. I reached out for help, consulted with others, and persisted in the problem solving process. This is far from a perfect design, but it's something that I wish all kids would have a chance to experience, seeing their final product actually get printed for them to be proud of.
If you have recommendations to modify the design, or would like one of your ideas come to fruition, please let me know in the comments or find me on Twitter. Thank you!
Happy Dumbfounded/Confused Fishing