Print-in-Place Engine Aims To Be The Next Benchy

While there are many in the 3D-printing community who loudly and proudly proclaim never to have stooped to printing a 3DBenchy, there are far more who have turned a new printer loose on the venerable test model, just to see what it can do. But Benchy is getting a little long in the tooth, and with 3D-printers getting better and better, perhaps a better benchmarking model is in order.

Knocking Benchy off its perch is the idea behind this print-in-place engine benchmark, at least according to [SunShine]. And we have to say that he’s come up with an impressive model. It’s a cutaway of a three-cylinder reciprocating engine, complete with crankshaft, connecting rods, pistons, and engine block. It’s designed to print all in one go, with only a little cleanup needed after printing before the model is ready to go. The print-in-place aspect seems to be the main test of a printer — if you can get this engine to actually spin, you’re probably set up pretty well. [SunShine] shares a few tips to get your printer dialed in, and shows a few examples of what can happen when things go wrong. In addition to the complexities of the print-in-place mechanism, the model has a few Easter eggs to really challenge your printer, like the tiny oil channel running the length of the crankshaft.

Whether this model supplants Benchy is up for debate, but even if it doesn’t, it’s still a cool design that would be fun to play with. Either way, as [SunShine] points out, you’ll need a really flat bed to print this one; luckily, he recently came up with a compliant mechanism dial indicator to help with that job.

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JB Weld – Strong Enough To Repair A Connecting Rod?

JB Weld is a particularly popular brand of epoxy, and features in many legends. “My cousin’s neighbour’s dog trainer’s grandpa once repaired a Sherman tank barrel in France with that stuff!” they’ll say. Thankfully, with the advent of new media, there’s a wealth of content out there of people putting these wild and interesting claims to the test. As the venerable Grace Hopper once said, “One accurate measurement is worth a thousand expert opinions“, so it’s great to see these experiments happening.

[Project Farm] is one of them, this time attempting to repair a connecting rod in a small engine with the sticky stuff. The connecting rod under test is from a typical Briggs and Stratton engine, and is very much the worse for wear, having broken into approximately 5 pieces. First, the pieces are cleaned with a solvent and allowed to properly dry, before they’re reassembled piece by piece with lashings of two-part epoxy. Proper technique is used, with the epoxy being given plenty of time to cure.

The result? Sadly, poor — the rod disintegrates in mere seconds, completely unable to hold together despite the JB Weld’s best efforts. It’s a fantastic material, yes – but it can’t do everything. Perhaps it could be used to cast a cylinder head instead?

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3D-Printed Parts Torture-Tested In Nitro Engine — Briefly

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.

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