New Light Switch - 3D Printed!

[flux3d]

As I discussed with quite a few people at the weekend I've decided to try and replicate a few of the cars plastic parts using the 3D printer I have access to. Now, there are quite a few potential candidates for replication, but the one I decided to start with is the humble light switch.

Mine has seen better days, with much of the black being worn away, revealing the white plastic underneath. I've tried re-creating a transfer to cover the problem area, but this soon fell off. So I chose to put up with it have an "aged" look. But with access to some new tech, and using my skills with 3D CAD packages I've started the process.

Here is the first version, modeled up and ready to go. I've not printed the full part yet (that's for tomorrow). Couple of tweaks to do yet, mainly to get a perfect fit for the lower part of the switch. I printed a few mill of the lower section and it needs slightly enlarging, but will do that tomorrow. In the meantime here are the CAD results so far.

The final picture shows it ready for printing. The red colour denotes one nozzle of the printer (to be loaded with black ABS) and the white symbol will be printed in white ABS using the other nozzle.

I'll upload pictures of the part tomorrow hopefully.

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[Admin-bloke]

Looks great !

[jwrayth]

Looking good!

If you ever decide to make a Rear-Fog switch for the centre console that has a translucent logo so it can be illuminated... well then sign me up Would love to get rid of the switch I have at the moment!

[RobvdVeer]

How smooth can we 3D-print these days? I am still thinking in terms of 'layered objects'. How much did it mature in the last few years?

[flux3d]

Ahead of you there with the dummy switch. I've got the usual fog light mod switch and would love something more refined.

As for the smoothness it can be very impressive. Might need a slight rub down. We'll see.

[A Van]

Nice work , can you look at the mirror switch blanks ?
With them we can fit the Saab switches easier

[flux3d]

Time for an update I think. Been working on getting these right, but work has gotten in the way a bit. However, had chance today to sit down and work on it. One of the problems is just getting used to the constraints of the machine itself, surface finish ect. Also, the tolerances on the switch are quite fine, so I've been through a few versions, tweaking things as I go.

Anyway, I've now changed my approach. Rather than trying to print the whole switch as one (with the symbol section as part of the build) I've moved over to printing the main body, and then creating the symbol part separately using a laser cutter and engraver. This will give people the option of different coloured light switch centres, plus different symbol designs as well.

I'll be printing these tomorrow so I'll keep you all updated.

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[A Van]

Nice attention to detail, different colour centres is a great idea

[RobvdVeer]

The screenshots do look promising

[flux3d]

Well, it's about time for an update. I've had the latest version printed up a couple of times, and made a few refinements again (wall thickness of the base as well as a couple of other issues) and I'm glad to say that I now have a really accurate part. It fits to the original switch perfectly, securing with a positive click as the lugs on the sides locate, but at the same time is easy enough to remove when you need to. It also slides perfectly in and out of the main body of the switch. With regards fit it an exact replica.

Now, I've been experimenting with getting the surface finish perfect, as well as creating the centre "illuminated" symbol. With regards the finish I'm just about there. The raw parts comes out reasonable well, but need a careful rub down, polish, primer coat and top coat to get a perfect finish. The first one I've produced also has a textured paint applied to it, to try to replicate the texture of the original, then a top clear coat. This is a little more of a gloss finish than I would like so I'm going to experiment a bit more. But for a first attempt I'm pretty please.

The centre illuminated symbol has taken a lot of trial, error and experimentation to get right, using a combination of techniques. However, what I've produced today I'm really pleased with, and will allow ANY symbol, artwork, logo ANYTHING to be reproduced. I couldn't resist doing the DMC company logos as an experiment. You can also have a range of colours for the illumination, so anything is possible. An illuminated panel for the door comes to mind, especially for the mirror switch area. The DMC logo would look especially nice there.

Anyway, here are some pictures. Not the best. Natural light would be the best to show the part off, but I'll try to do that soon and post up.

Let me know what you think guys.

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