3D printed intakes

[BOOT]

Had an idea not too long ago with my TPI intake, what if I 3D printed some runners or a plenum? The TPI intake seems like a great candidate for this tech and maybe some other efi intakes. Then I remembered AFR new plastic intake and wondered how long until someone prints a carb intake or just makes a sheet metal lower/valley cover and then just makes different plenum/runner combos to try out.

[BOOT]

Forgot to mention, you could even make the surface texture of the inside of the runner/plenum how ever you wanted.

[BOOT]

Never used pipemax, but if you had the right program I'm sure you could figure out a custom ideal intake for any combo, no more one size fits all.

[DaveMcLain]

This was done a long time ago I think using a process called stereo lithography. I was at the AETC which was sponsored by Superflow and Mike Chapman was giving a talk about cylinder heads. He was showing off this technology and at the time it was very expensive, fast but very expensive.

In today's world I'm sure it's much cheaper but still expensive to print such a large item. Now printing a runner to test on the flow bench or something similar would be quite practical.

[BOOT]

Still even if you could only print individual or paired runners and have a separate carb plenum, using a sheet metal base(back to the TPI kinda LOL).

[Billzilla]

Quite possible to do all that.
I've got a small 3D Printer - it'll do about a 130 mm cube - so I'd have to do the manifold in sections to be glued together later into one complete unit. There's larger printers (such as the Makerbot 2x) that'd work a bit better though.
Mine's a layer deposition machine so the finished part leaves thin ridges on the surface (about 0.2 mm thick) but they can be easily sanded off and also rubbed with a cloth soaked in acetone.

I believe it's also possible to use the ABS plastic they use to make a sand-cast mould, as the ABS burns away with no residue when the metal is poured in.

Anyway things like this are pretty easy to make ...


http://www.thingiverse.com/thing:25207

For the larger parts you slice them up in software, print them out, then glue them together.

[BOOT]

If it had to be done in sections I'd rather make something that would bolt together and use sealer or a gasket. Still a larger printer would be more ideal. But I suppose you could make a sheet metal plenum as well and just focus on runner size, shape, texture.

[Billzilla]

Good timing, I just found this ....

http://markforged.com

"The first carbon fibre 3D printer".

[ijames]

From last year: viewtopic.php?f=15&t=34511

[BOOT]

From last year: viewtopic.php?f=15&t=34511

Cool thx for the link, must have missed it in my search.

[RAS]

There's a 3D printed intake on one of Sonny Leonards Hemi Chevys. I think it's in Australia. Intake was done in California.

[csfx8588]

From what I understand a lot of OEMs are doing their prototypes this way. Rapid prototyping is getting cheaper since competition is going up, and depending on how big/material, isn't as expensive as you'd think. I'd just be worried about compatability with the fuel over time. I wouldn't use it in a forced induction application either.

I've even seen prototype exhaust manifold castings come into work, where the lost wax is rapid prototyped. No dies needed. Really cool stuff.

[Fordracer347]

Mine's a layer deposition machine so the finished part leaves thin ridges on the surface (about 0.2 mm thick) but they can be easily sanded off and also rubbed with a cloth soaked in acetone.

I was also wondering about the fuel compatibility issue until I reread this part.

[colebalster]

Here's an intake I designed. We had it printed to use as a fitment prototype prior to casting. We thought about running it on the dyno, but decided otherwise. Forget about the fuel concerns, the pressures inside the runners and plenum are far beyond the capabilities or the resin material. Each piece of this was printed in halves, and then glued together. Even if you "take it easy" on the dyno with the throttle, I think it would still burst or collapse depending on throttle activity.

If your only working with IR trumpets, they would probably work. But anything with a plenum and a throttle blade in front of it, and you're asking for trouble.




Cole

[1989TransAm]

Being able to test it in that form would sure cut down on time. So Cole, when is the new intake coming on the market? I have seen some blurbs on the internet about it and it sure looks like it has a lot of potential. If the dyno numbers are there I am wanting to buy one.