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Old 08-16-2018, 09:11 PM   #1
jpsuli
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Default 2nd Gen Interior Center Console Handle 3D Print Model

Hi Folks,

If you have a 2nd gen Saturn Armrest youll know those handles suck. They usually break at the circular ends. Last night I threw something together in Inventor and had it 3D Printed.

There are some improvements to be made, like making the supports on the circular joints much larger and indenting the space for the metal spring so it fits properly.

Here are the results:
saturncc.JPG
saturnccc.jpg

Here is the file:STEP.

If you print these, ENSURE YOU HAVE 100% FILL! These will break like toothpicks if you do not!

...
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Old 08-16-2018, 10:22 PM   #2
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

I 3D printed a coin holder a while back since I didn't have one and thought it would be cool to make. It turned out pretty well, I made the hooks a little to long but i just fixed it with velcro, didn't really feel like printing another one. Problem was though that I made it when it was still cold outside. Once the weather warmed up and the car started to get 90+ degrees inside, the plastic didn't hold up to well. I'm pretty sure it only warped like that was because of the weight from the coins dragging it down due to the plastic being soft from the heat. It probably be fine today if i never put any coins in it but then what would be the point of making it, lol

Hopefully your thing holds up better than my thing did, it probably will though sense its not really holding any weight.

http://www.saturnfans.com/forums/sho...59#post2265759
http://www.saturnfans.com/forums/sho...62#post2271362
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Old 08-16-2018, 10:36 PM   #3
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Defiantly keep us updated though on if you make any future revisions. I'l love to have one printed

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Old 08-16-2018, 11:27 PM   #4
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Quote:
Originally Posted by Zeebins View Post
I 3D printed a coin holder a while back since I didn't have one and thought it would be cool to make. It turned out pretty well, I made the hooks a little to long but i just fixed it with velcro, didn't really feel like printing another one. Problem was though that I made it when it was still cold outside. Once the weather warmed up and the car started to get 90+ degrees inside, the plastic didn't hold up to well. I'm pretty sure it only warped like that was because of the weight from the coins dragging it down due to the plastic being soft from the heat. It probably be fine today if i never put any coins in it but then what would be the point of making it, lol

Hopefully your thing holds up better than my thing did, it probably will though sense its not really holding any weight.

http://www.saturnfans.com/forums/sho...59#post2265759
http://www.saturnfans.com/forums/sho...62#post2271362
Did you use PLA or ABS? I would agree that the added weight probably caused the warping. I've never had experience with 3D printed models warping, though I never had them in a car on a 100+ degree day! I am making models from PLA but will be able to do ABS later, hopeful the ABS will stand up to much high heat without warping.

Second revision will be made tonight, hopefully I can fix the small issues on the first batch. Starting October, I should be able to make these in bulk, hopefully I can send them to members here, as i know not many have 3D printers that can be used.

The only issue I see is that the metal spring will differ depending on where people source it from, I may try to make the spring from something else that can easily be replicated.

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Old 08-16-2018, 11:52 PM   #5
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Quote:
Originally Posted by jpsuli View Post
Did you use PLA or ABS? I would agree that the added weight probably caused the warping. I've never had experience with 3D printed models warping, though I never had them in a car on a 100+ degree day! I am making models from PLA but will be able to do ABS later, hopeful the ABS will stand up to much high heat without warping.

Second revision will be made tonight, hopefully I can fix the small issues on the first batch. Starting October, I should be able to make these in bulk, hopefully I can send them to members here, as i know not many have 3D printers that can be used.

The only issue I see is that the metal spring will differ depending on where people source it from, I may try to make the spring from something else that can easily be replicated.
Honestly, I have no idea what kind of plastic was used. I asked the CAD teacher at my school if he could print it for me. Never thought of asking at the time, really should have though. I feel like it was PLA with how brittle the thinner prints always where. There was a "normal" printer and a resin printer but I know it wasn't made with that one. Resin is more brittle than PLA anyway

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Old 08-17-2018, 06:01 AM   #6
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

As this technology expands, we should be printing almost any needed part in the future. The $$ to be made will most likely be in the raw materials, much like the expensive ink cartridges for the color printers we buy today.

Printing up a good top engine mount is still a few years away.

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Old 08-17-2018, 03:44 PM   #7
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Quote:
Originally Posted by dummo View Post
Printing up a good top engine mount is still a few years away.
More like a few thousand years. Plastic is one thing, but printing steel , aluminum and rubber for general consumer use......

They didnt even have that in, Back to the future ;-)

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Old 08-17-2018, 06:24 PM   #8
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

I agree a Saturn engine mount would be hard to print. But on Sonexbuilders forums there is a guy printing airplane engine mount bushings. At work we bought 3D printed metal parts. The future is closer than it ever has been!

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Old 08-17-2018, 09:39 PM   #9
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

I know metal can be printed on a consumer level based on pretty much every online 3D printing services I look at. It's always the most expensive, that little latch for example was $30 on one website I looked at vs 5-7 for PLA or ABS plastic, but definitely possible. As for rubber, that's not currently possible with the technology we have now. Rubber doesn't heat up nicely like plastic or metal, it likes to burn when heated rather than melt into a formable shape like plastic. So one day we'll probably be able to make metal as inexpencive as plastic parts as technology improves and all that stuff. (Look how expensive it was to get a basic plastic 3D printer 10 years ago!) Rubber for a mount though will probably be a little while out.

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Old 08-17-2018, 11:09 PM   #10
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

The Sonex guys print bushings using ninjaflex.
http://www.sonexbuilders.net/viewtop...bushing#p30025

https://ninjatek.com

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Old 08-18-2018, 10:21 AM   #11
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

I made a handle out of galvanized steel, works well but is too bulky. Once I am at college in a week or two I'll print your version. Especially since it looks so much nicer and will probably work better than clunky metal.

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Old 08-18-2018, 10:24 AM   #12
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

How do you put the new latch in? Maybe it would be obvious if I had a part next to it but I haven't printed one yet and I never had an old one to reference to.

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Old 08-18-2018, 12:57 PM   #13
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Revision 2 has been made, will print it on Monday. The original design won't fit without modifications as the supports are actually too long, something like .01 inch. The new design also creates an indent so the metal clip from an original can stay clipped in.

In order to install these, there are 4 screws under the armrest that once taken out you must forcefully remove the plastic from (expect broken clips from the brittle plastic). That's it to get to the latch.

I'd upload the file but I'm on mobile right now.

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Old 08-18-2018, 04:42 PM   #14
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Quote:
Originally Posted by jpsuli View Post
Hi Folks,

If you have a 2nd gen Saturn Armrest youll know those handles suck. They usually break at the circular ends. Last night I threw something together in Inventor and had it 3D Printed.

There are some improvements to be made, like making the supports on the circular joints much larger and indenting the space for the metal spring so it fits properly.

Here are the results:
Attachment 53915
Attachment 53916

Here is the file:STEP.

If you print these, ENSURE YOU HAVE 100% FILL! These will break like toothpicks if you do not!
I think you just 3D Printed the most expensive part out of the entire CAR for a second gen interior......lolol.

The 2nd Gen Console handle/door hinge are the only part of a Saturn with a higher failure rate than Chrysler automatic transmissions......and THAT is not easy task.....lolol

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Old 08-18-2018, 04:45 PM   #15
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Quote:
Originally Posted by dummo View Post
As this technology expands, we should be printing almost any needed part in the future. The $$ to be made will most likely be in the raw materials, much like the expensive ink cartridges for the color printers we buy today.

Printing up a good top engine mount is still a few years away.
Standard manufacturing should still be lucrative for the upper mounts. We just need to find a shop or company willing to make them, because they will certainly sell.

The FLAPS replacement designs and brands are horrible for longevity, compared to original design. I wouldn't think they would be difficult to mass produce.

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Old 08-18-2018, 05:31 PM   #16
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Now that I'm thinking about it, why is the top mount so hard to replicate anyway? It's essentially just a slab of rubber with some metal around it, seems fairly simple. The OE mount must be using a really premium quality rubber or something if all the aftermarket mounts aren't anywhere near as good.

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Old 08-22-2018, 01:46 PM   #17
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Got revision 2 printed and it worked perfectly. Again, if you are printing these yourself, ensure its 100% fill and you may need to get a knife and poke out any gunk in the whole. I was quoted 20 dollars locally to do this print in black, because I only had white, so I just did white. If you need one of these printed and shipped or a key, you can PM me for the center console. I can begin making them mid-September.

center_console.jpg

Revisions made:
-Made the supports shorter, if you print the first one it will not fit without modification to the center armrest, this fixes that.
-A thinner hole for the metal spring, and an indent, so now if the spring is in the hole it will stay there
-made the clip that goes into the second piece longer, this allows the clip to lock properly with the *click* noise.
-Made the arc for the tip of the handle have a smaller radius so it'll have support for lower end printers.

Saturn2.JPG

Download STP File Link

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Old 08-22-2018, 09:34 PM   #18
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Do you have the drawing sheets for it, like cross sectioned with dimensions? We only have solid-works at school, and I'd like to possibly try and print one and ditch my metal bracket...

...
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Old 08-22-2018, 10:52 PM   #19
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

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Do you have the drawing sheets for it, like cross sectioned with dimensions? We only have solid-works at school, and I'd like to possibly try and print one and ditch my metal bracket...
Yes, I have a little notebook sketch with dimensions at work, I can get that the day after tomorrow (day off).

I use inventor, I believe Inventor is free to students provided you have a student email.

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Old 08-23-2018, 09:17 AM   #20
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Default Re: 2nd Gen Interior Center Console Handle 3D Print Model

Ill try downloading inventor, Ill do the sign up with my school. I am going to try to design door handles for the 1st gens, as mine are worn and floppy...
We should compile a list of things that can be printed, and work away it it.

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