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3D Printing Parts for the E46

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18K views 21 replies 10 participants last post by  azadani  
#1 · (Edited)
As I have people here who have/continue to generously give me and others their time and assistance, I've wanted to return the favors which is hard when you're an E46 noob.

I do have however, a bit of background in 3D printing, and have been active in helping new players get started in printing.

It seems there's some interest in the E46 on Thingiverse, which is the main repository for shared files.


I have 2 machines. One is a basic low temp PLA/PETG machine which is great for prototyping as it's quick and uses the cheaper materials. The other is a much more complex (and troublesome) custom enclosed machine which can run very high temps and exotic filaments, but is certainly not the first stop when designing prototypes.

If you want to get into printing, I can show you the absolute cheapest/best way to start, and help you dial it in.

If you want to design parts for the E46, I will run a few test prints for you and we'll see how they look. I use a free cad program that works well called "Design Spark Mechanical". If you use that you can email files to me that I can adjust etc with no losses or other issues with the files. It's actually a product selling tool from RS, but it's based on a very expensive program called "Spaceclaim". You just have to close the opening RS home page each time you open it. That's an Australian link, but it was Americans who put me onto this program years ago.


There are limitations with these sorts of parts, like dimensions, strength, UV/temp resistance etc. No point asking me to print a set of diff mounts or something, they won't work. Think of things like window winder brackets, accessory mounts, that sort of thing.

If you've already got a printer and are not happy with the results, you can post some pics and I'll try to point you in the right direction.

With these cars getting older and with the known fail points, possibly we could reinforce/replace some of the silly little plastic bits that break?

Please feel free to ask anything, and if this is the wrong place for this thread could the Mods please move it to where it would be more suitable.
 
#2 ·
#3 ·
And here's an example of a very handy part I designed for holding the Vanos assembly. Much better than flat soft jaws.


If you've got a printer, help yourself to it. Just use pretty much whatever material you've got in your printer, and throw it away when you're done.
 
#6 ·
Thank you for this. I do have a question. I have a plastic part (part of a window lift) and want to create a 3D file to share with others that can be used with a 3D printer. How do you generate the 3D files used to print when duplicating an existing plastic part? ? Is there a separate 3D scanner that should be used?
 
#7 ·
No problem at all. You've always been happy to help yourself, so I'm pleased to possibly return the favor.

The hobby grade 3D scanners (last time I checked) are more for artwork than engineering parts. They just don't replicate the dimensional accuracy.

The way you would do it would be with good old fashioned verniers. Pull the part out and look at where you think the weakness is and measure the critical dimensions like hole sizes, distance between centers, clearances etc. Then you make a design on CAD, export it as an .stl file and test print/fit it. Depending on the complexity of the design, you may have several to many tries at getting it right, but it's worth getting it perfect. You have the design file forever once you're done.

Another factor is how the file will print regarding thin walls, overhangs etc, but I'd rather explain those issues as real life examples arise.

Use the CAD program I mentioned in the OP, and I'll be able to help you more, and if you don't mind paying the postage at my cost I'll send you a bag full of whatever it is we've made for free. When I was really active in online printing, a plastics supplier sent me a large amount of PETG that he'd extruded, so as long as you don't mind testing in bright red drink bottle plastic we're all good.
 
#8 ·
I should point out that anything I design or help design, I will definitely put up on my Thingiverse page as a free non commercial download for anyone to download and use, along with tips on how to print it well.

I may also choose to print runs of that part in an exotic like polycarbonate or nylon etc, and sell it on ebay etc at my complete discretion. That's not a priority, but I'll make that clear as sometimes I do that to fund plastics/breakdowns/etc.
 
#14 ·
Just wanted to jump in ask if anyone found a suitable material for inside the cabin, I was prototyping a nice ashtray delete + phone holder but being in California the car was more then happy to warp the PLA
 
owns 2005 BMW 330i
#22 ·
Heaps of wall thicknesses and infill will help.

I'd also try a couple of raised sections on the outer diameter that you could lever with a bar or screwdriver, rather than a small hex nut in the center.

Is that up on thingiverse? I'm about to do a fuel pump, so if I can use the file I'll try to make it work and put some pics up here if you like.