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Re: 3D Printed Intake Manifolds
Posted: Thu Jun 06, 2024 6:16 pm
by yugami
I printed a couple other test pieces out of the material I started using above. I plan on torqueing a bolt down to 15ft/lbs (intake torque) between 2 pieces and testing it for deformation and creep, both in ambient and then heat it in my printers chamber and let it sit.
Re: 3D Printed Intake Manifolds
Posted: Fri Jun 07, 2024 1:16 pm
by TC72
I've printed lots of underhood parts in PC, including a MAP sensor bracket under a 951 intake manifold that is still in service 6 years later. I made a new cam gear housing for my 3L 16V(front and rear) in Nylon 6 with CF, including the cam sensor mount. I do the CAD, and a friend does the actual print. We're making a test piece to pressurize to nail down settings for something airtight under pressure/ vacuum.
My next project is an intake manifold for a 16V NA, and possibly the same for my turbo if it works well. It's important to melt in metal inserts for threads, and metal standoffs for through bolts. Even with 100% infill, printed parts are not that strong in compression.
Someone posted a model of a 968 manifold from grabcad - I've used that as the base for what I'm working on, but removed the plenum and extended the runners. Need to verify the length I can fit in the engine bay, and then sort out plenum design, throttle placement and diptick tube support. It's also designed to use M97 intake gaskets, the port shape and size is close enough.
One of the biggest issues is build volume, and supporting the shapes when you have critical, flat faces at odd angles. This will need to be 3 or 4 pieces, either bonded or bolted and sealed. Adding these features and breaking it into multiple parts later on is pretty easy.
Re: 3D Printed Intake Manifolds
Posted: Fri Jun 07, 2024 1:23 pm
by michaelmount123
Here's what I've been able to learn and to dig up:
1. Current pricing from AT Throttles for the system I purchased many years ago. It fits the intake manifold on the drawing.
2. Higher resolution scan of the intake drawing showing dimensions.
3. Photo of 3D printed test pieces that were made for test fitting. They need some revisions before usable as real pieces.
Another thought: A support bracket under the throttles would take the stress off of the intake pieces, and a insulator between the manifold and the cylinder head would minimize heat transfer.
Thank you for your enquiry. At this moment in time the pricing for the throttles as per the detail you sent 102-102-00073, 102-119-00002 and 101-131-00001 is as follows:
102-102-00073 £1247.00 / throttles and linkage
102-119-00002 £56.00 / TPS
101-131-00001 £21.25 / throttle cable
- 3DIntake.jpg (1.91 MiB) Viewed 1869 times
Re: 3D Printed Intake Manifolds
Posted: Fri Jun 07, 2024 1:40 pm
by michaelmount123
TC72 wrote: Fri Jun 07, 2024 1:16 pm
I've printed lots of underhood parts in PC, including a MAP sensor bracket under a 951 intake manifold that is still in service 6 years later. I made a new cam gear housing for my 3L 16V(front and rear) in Nylon 6 with CF, including the cam sensor mount. I do the CAD, and a friend does the actual print. We're making a test piece to pressurize to nail down settings for something airtight under pressure/ vacuum.
My next project is an intake manifold for a 16V NA, and possibly the same for my turbo if it works well. It's important to melt in metal inserts for threads, and metal standoffs for through bolts. Even with 100% infill, printed parts are not that strong in compression.
Someone posted a model of a 968 manifold from grabcad - I've used that as the base for what I'm working on, but removed the plenum and extended the runners. Need to verify the length I can fit in the engine bay, and then sort out plenum design, throttle placement and diptick tube support. It's also designed to use M97 intake gaskets, the port shape and size is close enough.
One of the biggest issues is build volume, and supporting the shapes when you have critical, flat faces at odd angles. This will need to be 3 or 4 pieces, either bonded or bolted and sealed. Adding these features and breaking it into multiple parts later on is pretty easy.
Love this, but where are the throttles?
Re: 3D Printed Intake Manifolds
Posted: Fri Jun 07, 2024 3:03 pm
by cp99
@michaelmount123
Is this the intake kit you’re referring to that uses the AT throttles? Found this on the other website / google.
Re: 3D Printed Intake Manifolds
Posted: Fri Jun 07, 2024 3:09 pm
by michaelmount123
cp99 wrote: Fri Jun 07, 2024 3:03 pm
@michaelmount123
Is this the intake kit you’re referring to that uses the AT throttles? Found this on the other website / google.
No. That system came from Dave Finch at Raetech in MI. The cost was astronomical.
Re: 3D Printed Intake Manifolds
Posted: Sat Jun 08, 2024 8:30 am
by TC72
@michaelmount123
I was planning for this to be a single throttle setup with a plenum, it allows a lot more flexibility in runner shape and length. I have another version for throttles using some IDA based units, but I haven't put much time into it. Always hard to get around the booster.
Re: 3D Printed Intake Manifolds
Posted: Tue Jun 18, 2024 8:54 am
by yugami
I had some freetime last night and took a swing at doing a dxf for the mounting face based on the PDF provided.
I essentially outlined the pencil drawing as best I could using splines, there are a couple tiny oddities I may be able to work out later, but all in all it appears to be fairly good.
Hole position was within .03mm based on me eyeballing it so I feel that the outline geometry should be reasonably accurate. I made the mounting holes to print.
I then extruded a solid from it 15mm thick and used direct modeling to increase the diameter of the holes to 11.8 (from 8.15) to allow for compression limiters to be inserted later (mcmaster part number 91868A436).
I'm going to do a test print of just 1/4 of the overall part later today if time allows.
If my intake gaskets ever show I I'll be pulling the intake soon and I can do a test fit at that time.
I'll make a post in the 3d print area to attach some of the technical files as the main forum doesn't like those.
Re: 3D Printed Intake Manifolds
Posted: Tue Jun 18, 2024 9:29 am
by yugami
TC72 wrote: Fri Jun 07, 2024 1:16 pm
One of the biggest issues is build volume, and supporting the shapes when you have critical, flat faces at odd angles. This will need to be 3 or 4 pieces, either bonded or bolted and sealed. Adding these features and breaking it into multiple parts later on is pretty easy.
Part of the reason I've personally been focused on PC and PC blends. Viable solvent welding vs PA. Though if we're not adverse to a 2 part gun style adhesive Infinity Bond makes a couple interesting products that might work well on pa-cf
Re: 3D Printed Intake Manifolds
Posted: Tue Jun 18, 2024 1:22 pm
by Tom
I put your STL on my Bambu X1C just to see. I had to split it in two, but Bambu adds automatic connectors that hold it together surprisingly well. I could see it being designed in 3 pieces, with the two outer ports/pieces each having two bolt holes, and the two inner ports being one piece with 3 bolt holes. I assume this is for a 16 valve head, as the ports are slightly different than either of the 8 valve ports. Printed in green ABS, since I had it spooled up and ready to go.
- manifold.jpg (391.51 KiB) Viewed 1693 times
IntakeManDrwg.pdf