Fully 3D Printed DIY electric car
 

Fully 3D Printed DIY electric car  

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Gonper
(@gonper)
Eminent Member

I managed to design a glue for PLA plastic that actually creates stronger bondings than epoxy ones.
More than a glue is a chemical welding product. It is made with a solvent (Dichloromethane) PLA as filler.
It really works well in PLA, PLA+ and PETG but need some more test in this last one. And it works perfectly for big parts like this project needs.
I am now working in the proportions (Filler/Solvent) in order to get the best results and easy to use. I will make a short of a manual of how to make it when finished.

Hope this helps to others.
Made a vido comparing different bonding systems:

Posted : 25/01/2021 12:17 pm
Gonper
(@gonper)
Eminent Member

I managed to design a glue for PLA plastic that actually creates stronger bondings than epoxy ones.
More than a glue is a chemical welding product. It is made with a solvent (Dichloromethane) PLA as filler.
It really works well in PLA, PLA+ and PETG but need some more test in this last one. And it works perfectly for big parts like this project needs.
I am now working in the proportions (Filler/Solvent) in order to get the best results and easy to use. I will make a short of a manual of how to make it when finished.

Hope this helps to others.
Made a vido comparing different bonding systems:

Posted : 26/01/2021 12:19 pm
Gonper
(@gonper)
Eminent Member

First parts just come out of the printer (door parts+), all looks good so far.
Next step chemical welding.

Posted : 01/02/2021 11:58 am
Clemens M.
(@clemens-m)
Honorable Member

Used filament is PLA or PETG?

Best regards, Clemens

Posted : 01/02/2021 12:01 pm
Gonper liked
Gonper
(@gonper)
Eminent Member
Posted by: @clemens-m

Used filament is PLA or PETG?

Best regards, Clemens

Hi @clemens-m 

I am using PLA PLUS from Sunlu, reasonable priced and tough as nail.
But not sure if I have selected a nice color for the door...

BTW, I am putting together a Hackaday project with info and updates here:  https://hackaday.io/project/177105-jellybean3d-printed-car

This post was modified 3 weeks ago by Gonper
Posted : 05/02/2021 8:18 am
Clemens M.
(@clemens-m)
Honorable Member

I am sure you will need  a second loop - so I think colour is not important for the moment and there is still the possibility of painting. Do you think that heat resistance of PLA is enough?

Best regards, Clemens

Posted : 05/02/2021 12:37 pm
Gonper liked
Gonper
(@gonper)
Eminent Member

Yes, the painting option is always there...

Certainly PLA low heat resistance is something to take into consideration.
That is why I decided to use PLA+ that is has around 5ºC to 10ºC higher resistance, I think that with that will be enough for most of the time. 
But I live in a very hot area (South of Spain) and I plan to use this vehicle for just short commuting (5-15Km, occasionally 40Km), most of its time it will live in a garage, but when outside I have to be careful not to park it in areas where it can overheat due to IR reflections or concentration.

The parts that are close to the motor and brakes are going to be made in PA.

 

Posted : 08/02/2021 10:26 am
Clemens M.
(@clemens-m)
Honorable Member

@gonper

Hallo,

have you done a rough estimation of weight of your vehicle. And do you need a certification of it to be allowed to drive on official roads? Still very interesting project! Have you done a bit of how much time you invested to design it. It must be lots of hundred hours?

Best regards, Clemens

Posted : 08/02/2021 7:04 pm
Gonper
(@gonper)
Eminent Member

have you done a rough estimation of weight of your vehicle.

  • Estimated Vehicle weight 75 to 85Kg (Final weight may vary depending on printing material/s, printing adjustment and components chosen)
  • Cargo capacity: Driver + cargo = 130Kg maximum (estimation)
  • Weight estimation for 3D printed parts is around 35 to 45Kg (It will vary depending on the material/s chosen and printing adjustments)

And do you need a certification of it to be allowed to drive on official roads?

I live in the EU so yes, you need a certification/homologation for everything, even just for waking up in the mornings...
I do not have the money or resources to do a fully certification. So I will sneak it into the e-bike type.

Have you done a bit of how much time you invested to design it. It must be lots of hundred hours?

With big projects like this, it is counted in thousands of hours, and I am still around half way... 🙄 
Anyway it is a hobby project so I am enjoying it.

 

 

This post was modified 3 weeks ago by Gonper
Posted : 09/02/2021 10:59 am
Clemens M.
(@clemens-m)
Honorable Member

@gonper

Have you read through this?

https://blog.prusaprinters.org/de/der-grosse-leitfaden-zum-kleben-und-zusammenbauen-von-3d-drucken_44908/

Also available in English - maybe some interesting additional information?

Best regards, Clemens

Posted : 25/02/2021 4:30 pm
Gonper
(@gonper)
Eminent Member
Posted by: @clemens-m

@gonper

Have you read through this?

https://blog.prusaprinters.org/de/der-grosse-leitfaden-zum-kleben-und-zusammenbauen-von-3d-drucken_44908/

Also available in English - maybe some interesting additional information?

Best regards, Clemens

Thank you Clemens, I read it. Their results mach my research. But most of the tips there are for figurines and display object but not for functional parts, except for the CA different bondings.
And I think that instead of the Pattex "1 for all" they should recommend the Pattex PL600 or its equivalent Sikaflex -11FC+ that are better suited for plastics materials.

Posted : 01/03/2021 11:50 am
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