Prototype number 1

I can't say what it is because I'll be applying for a Patent after the concept has been cleared from Bayliss Brands.  The chap who created the clockwork radio as well as many other inventions.

Edwards Products prototype assembly

I can however talk about the process of 3D printing and this is my first attempt.  Should anyone be interested.

Above is a render of an assembly of parts created in the CAD program Solid Works.  It's quite a complex mechanism inside but you're not going to see that.

With the finished assembly file (about 50-100hours work) I emailed it thinking it'll be printed immediately and I'll screw it together and it'll work.   Not quite that easy however.

I was told to rebuild the assembly making parts much thicker because even though the machine it was printed on is the best machine you can get, (costing £100k) thin plastic parts, especially spring loaded parts were liable to snap.
I was told holes for screws are best tapped afterwards rather than modelling in the screw thread.
Clearances for sliding parts should be loose at least 0.3mm and from this experience I'd say 0.5mm is better.

What's involved
When the assembly of parts come out of the machine they are laid on a sheet of thick clear plastic.  You have to prize the parts from a lattice support structure on the clear plastic with a knife (feeler gauges are good).  Then all the nooks and crannies have to be scraped to remove the support material, which takes hours!  A dental pick set is good for this.
A fair bit of sanding with sand paper and needle files is also called for.
Modelling in a way to reduce scraping and picking is well worth it.

Assembled 3D printed prototype

 Does it work?

I'm afraid not. It's to do with distances, so there'll be an EP002 coming soon.

Lessons learnt

It's a little expensive (several hundred quid) but infinitely cheaper than if you machined the parts out of metal. 

It would be nice if it was possible to use transparent plastic to see how the mechanism works (or not work) 

It would've been wise to print several version of parts so you can try more things out without constantly badgering for a week a very busy factory boss.  

The bit I found strange was, the models and assemblies created in the computer, that you can zoom in and out of on the screen, are now physical, and tiny in your hands.  It feels a bit like drawing on a piece of paper and wishing there was an undo button to correct a mistake.  

Cheers,

Rich