Lawnmower broken wheel. Honey, what for you have all your tools ?

[Gennady]

Day ago my older lawnmower pusher started to show some age. I was already looking at possible replacement but my better half asked me very valid question - why do you have your expensive tools and nice workshop if you can't fix this simple thing, Here are photos of the broken hub for the wheel.

I made a 3D scan with my iPhone and it turned out to be quite good. Here is the scan.

After that replacement hub was designed and 3D printed with aluminum cast in mind.

 

[Tom O]

I haven’t really used that feature yet

 

[DavidR8]

@Gennady did you use a scanning app?

 

[Tom O]

II belive it’s Scaniverse

 

[slow-poke]

I have been patiently waiting for the Star Trek Replicator. I had no idea it had already arrived.

 

[Gennady]

did you use a scanning app?

Yes, It is KIRI. They have free license with limited number per month of processed/rendered models. It uses IPhone camera, then stitches 70 images, for free license, into 3D object and gives you download link. Works quite well for my purposes.

 

[Gennady]

Printed with and without fillets/drafts, primed and painted. will see how it will be released from the sand.

 

[Tom O]

Are you using any sand cores?

 

[kevin.decelles]

I recently did something similar by printing new hubs for my lawn sweeper. Printed out of petg-carbon fibre

I’m trying them as-is for now and on 75% infill they are holding up.

 

[Gennady]

Hub poured, machined drilled and attached to wheel. there are few defects in aluminum - i think it is non-critical at all. I made a several attempts of pouring and there were qute a few defects - i was suspecting too wet green sand. after a fair bit of experimenting I pored open mold. that produce quite a waste of aluminum which I deleted with lathe, saw and file Anyway - mower is mowing, everybody is happy

 

[Gennady]

Are you using any sand cores?

No, too advanced for me. I don't have any liquid glass and CO2 setup, I read people also using epoxy with quite a success. I will try next time - i have another project coming.

 

[Gennady]

Printed out of petg-carbon fibre

@kevin.decelles . Nice looking hub. I know this stuff is very abrasive. Do you use special printing nozzle ?

 

[Tom O]

I think we are screwed for casting in Calgary for apparently 3 to 5 weeks due to the water shortage for any source of open flame mind you it will give me a chance to try out the electric one I bought a few months ago. I still have to temper the sand that has been sealed up for the last couple years.

 

[kevin.decelles]

@kevin.decelles . Nice looking hub. I know this stuff is very abrasive. Do you use special printing nozzle ?

I’m using standard nozzles, and have only started to see some variations after printing 1kg of filament.

 

[jcdammeyer]

Hub poured, machined drilled and attached to wheel. there are few defects in aluminum - i think it is non-critical at all. I made a several attempts of pouring and there were qute a few defects - i was suspecting too wet green sand. after a fair bit of experimenting I pored open mold. that produce quite a waste of aluminum which I deleted with lathe, saw and file Anyway - mower is mowing, everybody is happy

Nice to see someone else casting.

 

[Dan Dubeau]

Great job. I have 3d printed patterns for sand casting many times. Such an awesome capability to have in the shop.

Glad you were able to prove the value of your tools and shop to the better half. A monumental victory!