Additive manufacturing has come a long way in a short time, and the parts you can turn out with some high-end 3D-printers rival machined metal in terms of durability. But consumer-grade technology generally lags the good stuff, so there’s no way you can 3D-print internal combustion engine parts on a run of the mill printer yet, right?
As it turns out, you can at least 3D-print connecting rods, if both the engine and your expectations are scaled appropriately. [JohnnyQ90] loves his miniature nitro engines, which we’ve seen him use to power both a rotary tool and a hand drill before. So taking apart a perfectly good engine and replacing the aluminum connecting rod with a PETG print was a little surprising. The design process was dead easy with such a simple part, and the print seemed like a reasonable facsimile of the original when laid side-by-side. But there were obvious differences, like the press-fit bronze bearings and oil ports in the crank and wrist ends of the original part, not to mention the even thickness along the plastic part instead of the relief along the shaft in the prototype.
Nonetheless, the rod was fitted into an engine with a clear plastic cover that lets us observe the spinning bits right up to the inevitable moment of failure, which you can see in the video below. To us it looks like failing to neck down the shaft of the rod was probably not a great idea, but the main failure mode was the bearings, or lack thereof. Still, we were surprised how long the part lasted, and we can’t help but wonder how a composite connecting rod would perform.
Still in the mood to see how plastic performs in two-stroke engines? Break out the JB Weld.