Large Scale Central

Boron Station in 3D

Modeling Technical Modeling
#1

Very new to 3D printing, but have learned a lot in about one month! Been using Tinkercad to make windows, doors, and a draw bar (replacing a broken one). Easy to use, on-line, and it works for both PC and Mac computers.

New project is the Boron (CA) station as featured in GR, January 1994. Scaled it down to 1:32, and have printed the foundations and the “Boron” station sign. And I’ve designed a side and the rear walls. Beginning to look OK

Hardest part will be to do the bay window in Tinkercad. But an interesting project. I’ll add some pictures as I progress.

#2

Here is a picture of the completed foundation and the rear wall. Rear wall and window is printed in a single piece, while the glazing is cemented in afterward. Foundation is a separate set of printings (one front, one rear, and two each for the sides) because the printers couldn’t do the height of the foundation AND the wall.

#3

looking very nice Dick, 3d Printing can have a big learning curve. One not only has to be able to use #D Cad but also needs to know the limits of the specific machine you are printing on. If you get in to under hangs or shallow angles problems will surface and you have to be able to adjust the printer or you drawings to rectify. Looks like you are off to a great start though. Keep them pictures coming!

#4

You are so correct, Randy. The plans come from the January 1994 Garden Railways magazine. I had them resized for 1:32, and found that that the reduced plans didn’t agree with my scale ruler! Then, the 3D printer has an ample (for most model scales) bed, but not big enough for 1:32 or larger! So I had to remove the foundations from the walls. Then I had to create lap joints to hold them together, and other lap joints to put the two pieces of the side foundations together. The ends can be done in a single print (each), but the front has a bay window that I have to figure out how to design, fit into the space, and glue up.

I came up with a way to tie the wall sections together with splines, and did a small test of it today. It seems to work, hope it will scale up OK. Live and learn, or stop learning, stop living. It’s keeping me thinking and hanging out with young(er) folks so it’s not all bad.

Today’s project was to do the front, but the printer had problems and I ran out of time, so I made some corner pieces (90º triangles) to hold the foundation and the walls at right angles.

#5

I haven’t forgotten about this project. Club members have asked for small items, so I’ve been neglecting Boron. This week I finished one side (24 scale feet) of the station. Now I’ve got foundations, the rear wall and one side. Starting to look like a station.

#6

Now I’ve got all four sides (including the front with the bay window), the signs, and the foundations completed. Haven’t assembled it yet due to other projects. Will work on it again after I finish the trainman’s shanty in this month’s MR.

#7

I came up with a way to tie the wall sections together with splines, and did a small test of it today.

i would be very interested in pics about that, if you are willing to share.

#8

The long walls were too long for the Makerbot 2. So I cut the wall one third/two thirds using netfab , a free program found on the internet. As I designed the long walls, I inserted a rectangular hole for a spline inside the wall, then cut the wall on the spline. SThen I designed the spline about 1mm smaller and 1mm thinner than the rectangular hole. I don’t have any pictures of this operation, but I do have a picture somewhere of the completed wall.

You may already know this – I didn’t. You can’t put a 2mm rod into a 2mm hole. The rod has to be a little smaller, and 1mm less seems to work for me. Also, if you use the “High” resolution, you’ll get a smoother finish on the print. I’ve also found that priming the PLA (necessary if the print is to be used outside as PLA is not UV resistant) with an aerosol auto body primer which has some “body” and fills the low spots. A little sanding and you’ve got a smoother base for your final coats!

#9

thank you.