Fully 3D Printed Functional MK 42 !! :0

Quick pics update as I run to work!

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Welded most of the pieces I have so far on the boot just this aft after a long morning of meetings.

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Getting the workflow down on the CNC machine and will cut out these pieces in aluminum next time I'm over there! :)
 
Looking good mate. What 3D printer are you using by the way? I was looking at the Makerbot 2 any ideas how they are to use and any issues like warpping and that stuff?
 
Got up this morning with the goal of getting those arms CNC'd out and was able to get lots done today. The machine kept slipping because of the pull from the bit and possibly my bumping the head plate here and there, but after several attempts and clamping down the plate with some large vice grips I was able to cut out some aluminum arms!

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Could these sponsors be anyone?

Yes, there will be a sponsors as well as donators page on the website when we get it up!

Looking good mate. What 3D printer are you using by the way? I was looking at the Makerbot 2 any ideas how they are to use and any issues like warpping and that stuff?

I am using the Afinia H-Series, which you could see some pics of near the beginning of the thread or on my blog. I just met Bre, the founder of Makerbot yesterday at a conference he was speaking at. I think they are a great company with an accurate printer but I don't think you will be pleased with PLA armor creation. I would strongly suggest using ABS because it adheres so well to itself and is very paintable and much more rigid.
 
First of all congrats, yours is an amazing and hard work :thumbsup

Now my question, will those sponsors get the 3D files so they can print a suit as well?
 
This is freaking EPIC! cant wait to see how the rest of the build goes

Hey thanks, thats quite a compliment. It would be epic if I had my own Titanium printing lab, but I am excited about the tools I can use for this armoring part of the suit prototype. Integrating the electronics we are working on and perhaps pneumatics will get me really excited in the near future. I looked at your thread, I like the giant LEDs you have going in the palm of the hand. :)

Wow, what a great job. Fantastic.

Thanks so much!

Hope all had a good Labor Day weekend, mine was relaxing and full of good times. Yesterday, I worked on creating these pieces:

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First of all congrats, yours is an amazing and hard work :thumbsup

Now my question, will those sponsors get the 3D files so they can print a suit as well?

Thanks! I will be laying out what the kickstarter/ sponsorship rewards would be beyond getting their names on the project and ads on our page. Having things like the boot model being sold would be good for some people, but there are still very few people who have a 3D printer or could manage to do the splicing and finish work time to create their own. I am considering putting the models on Shapeways for sale (which would be expensive for purchase there), but if there are enough sponsors who would pay for the boot model then I would probably distribute it all at the same time.
 
Here are some update pics as the printing on the calf commences! Yesterday I printed out the two mid calf pieces and right now printing the large lower mid section. Notice how flawlessly the calf is lining up with the shin! :)

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The top of the calf has two more pieces, which are just as large. Does anyone know what the best pre primer filler is for ABS? I am still searching and am not sure about Bondo. Someone told me Marine Filler, which may work for small peices, but I also want to find something that is not sold $220 dollars a gallon.
 
If it is rigid, I would just just Rage Gold, for a filler, and "icing" for fine filing..... Icing is extremely runny and a very nice self leveler.. rage gold runs approv 50-60 bucks a gallon, and icing is 20 or so a tube.. both are extremely easy to sand and have very minimal shrinkage over time.

Sent from my HTC One X
 
If it is rigid, I would just just Rage Gold, for a filler, and "icing" for fine filing..... Icing is extremely runny and a very nice self leveler.. rage gold runs approv 50-60 bucks a gallon, and icing is 20 or so a tube.. both are extremely easy to sand and have very minimal shrinkage over time.

Sent from my HTC One X

Hey thanks for the tip! I will read into those products, what would I search for with "icing?" I will have to wait on painting the boot until after the fair so I can focus on getting the mechanisms fit into it.


I'm on the final print right now for the boot V2!

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has anyone ever tried using a proffesional program like wildfire or Solidworks? I have access to both, i wonder how easy the "smoothing" would be? i woudl be wiling to try it if someone wanted to work on it with me! I also have access to a 3d printer but it looks like your printable area is larger than mine, i think i have about 10x9x8.

has anyone used either of these 3d modeling programs? i know i can open every type of 3d file known to man in Solidworks.

also Great thread by the way! AWESOME work! you will have to let me know if you run into any problems with fitment and interferance. and if you need any help with the articulation, our shop does automation, so i know a thing or two!
 
BOOT V2 PRINT COMPLETE!!!

As you can see there is warping on both parts of the mid-calf which will I will sand down on. It looks so friggin cool, I can't wait to sand and weld the calf tomorrow and then install the mechanisms by this weekend!!

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The icing is actually made by USC.... I couldn't remember if it was an evercoat product or not.... Here is an amazon Link for you ..

Amazon.com: USC Icing 24 oz tube - Glazing & Finishing Filler Putty: Automotive

Sent from my HTC One X

Ah, great thanks for this I will definitely test out this finishing product!


has anyone ever tried using a proffesional program like wildfire or Solidworks? I have access to both, i wonder how easy the "smoothing" would be? i woudl be wiling to try it if someone wanted to work on it with me! I also have access to a 3d printer but it looks like your printable area is larger than mine, i think i have about 10x9x8.

has anyone used either of these 3d modeling programs? i know i can open every type of 3d file known to man in Solidworks.

also Great thread by the way! AWESOME work! you will have to let me know if you run into any problems with fitment and interferance. and if you need any help with the articulation, our shop does automation, so i know a thing or two!

Well, Maya is about as professional as I know which is what I use. Solidworks seems like an interesting program and probably easier to learn than some 3D autocad programs right off. Maya does a great job at smoothing and rendering hard surface models. I do have access to several CNC machines, and metal shop tools for our aluminum custom parts to come. Thank you for the compliments and the offer to help with automation!
 
BOOT V2 PRINT COMPLETE!!!

Well, Maya is about as professional as I know which is what I use. Solidworks seems like an interesting program and probably easier to learn than some 3D autocad programs right off. Maya does a great job at smoothing and rendering hard surface models. I do have access to several CNC machines, and metal shop tools for our aluminum custom parts to come. Thank you for the compliments and the offer to help with automation!

well Solikdworks is a 3d modeling "creating" software that is about 10 times better than Autodesk (auto-cad/ inventor) you cando stress analysis as well as make the components the way you want. for instance you should be able to add posts (and sockets on the adjacent connecting parts) to the part you are working on so that you can cut down on your "welding/sanding/grinding time" its very simple. In the process probabaly about 20x's less labor intensive. especially since ABS plastic and bonding is cheap with dowl pins and matching holes (and some adhesive). also you could design and print the hinges into the model without having to cut anything.

let me know if you want me to try modeling a couple of pieces for you. worst case youre going to save a ton of time having to weld and sand pieces. if you have dxf files or any other type of file that can be opened and edited i can add anything you want to them. i have nothing better going on between grad classes so i can donate my time to the cause! :)
 
That boot looks great. Any more progress pictures?

Yes actually. I found a good gauntlet to test print out and get the arm control board fitted by next weekend's fair. So, I'm printing that out right now. It was made by "Abb Eliten," not sure if he made it but he printed out the forearm for the movie release back in May. Also, Im headed over to the shop to sand these calf pieces flat for welding.

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You made me cry again with those updates. Moar please :D

... hold your tears for when I can afford to buy a couple linear actuators :) Ohhh baby.
 
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