How about a 3d printed ER32 collet? Let's give it a shot.

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NT_2112

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I wanted to see if I could hold a square pen blank in an ER32 collet on my lathe.

So, starting with this:
image (35).png

I coverted the center hole into a square and 3d printed this design:
Screen Shot 2020-11-05 at 9.01.50 AM.png

And got this result before removing printing supports:

Screen Shot 2020-11-05 at 9.04.22 AM.png

And after cleaning it up a little:

Screen Shot 2020-11-05 at 9.03.12 AM.png



Hoping I get a chance to test it this week.
 
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MPVic

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Amazing ingenuity!!! Anxious to see how it performs. Curious about the material - can you utilize different materials to increase the strength of any "printed" item?
 

More4dan

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Very cool! I’ve seen nylon blanks machined for collets for sale for holding odd shapes. Should work. Might get away with fewer slots for something more flexible than steel


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NT_2112

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If anyone is interested in testing one out but doesn't have a 3d printer, let me know, I can mail you one.

I'm designing a .75" square one right now.
Screen Shot 2020-11-06 at 1.09.21 PM.png

Sadly, it doesn't look like I can do a 1" square.
 

RobS

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Actually looks like an ER-40 would work.
However, I do not know what lathe you are using.

ER ColletLengthDiameterClamping Range
ER-11​
18 mm (0.71")11.5 mm (0.45")0.5—7 mm (0.020—0.276")
ER-16​
27.5 mm (1.08")17 mm (0.67")0.5—9 mm (0.020—0.354")
ER-20​
31.5 mm (1.24")21 mm (0.83")1—13 mm (0.039—0.512")
ER-25​
34 mm (1.34")26 mm (1.02")1—16 mm (0.039—0.630")
ER-32​
40 mm (1.57"33 mm (1.30")1—21 mm (0.039—0.827")
ER-40​
46 mm (1.81")41 mm (1.61")3—26 mm (0.188—1.024")
 

More4dan

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I would like to give a 3/4” square a try. I wonder how a round version would work on holding a pen without marking it. Just a thought. I’d happily pay postage to get one to play with.

Danny


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randyrls

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I find that metal working and woodworking tools "cross-use" very readily. They make R8 collets without a hole in them so you can machine your own recess (possibly off-set) in the collet end . I never seen the same thing for the ER series.
 

bmachin

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Regarding the ER40. I was just checking the dimensions online and found that the groove that snaps into the nut has a diameter of 36.2 mm (1.42"). Since the diagonal of a 1" square is 1.41" ER40 seems to be a dead issue although you could remove or shorten the collet segments at the corners of the square.

By the same token the diagonal of a 3/4 square is 1.06 and the diameter of the comparable groove on the ER32 is 1.15. Not a lot of material left at the corners. It will be interesting to see how it works out.

Bill
 

Jarod888

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I would love to try one out. I'll send you a pm.

I would be very interested if you made one in 1/2 inch square or 12.5 to 13mm.
 
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Curly

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5C are a lot longer collet and a chuck for one would be too big for a 7x14 mini metal lathe being discussed. I have a 5C chuck for my 13x37 metal lathe and it is at least 10 pounds. The 5C collet is drawn into the chuck by a thread at the back end of the collet which would be difficult to setup on a mini lathe.
 

NT_2112

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Looks like I have 3 people interested in being beta testers. That should be plenty for now. Thanks for the interest. I'll follow up via the IMs.
 

NT_2112

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Quick update.

Was able to print the .75" square one and test it.

Screen Shot 2020-11-09 at 7.58.31 PM.png




Screen Shot 2020-11-09 at 8.01.43 PM.png


I'm pretty happy with it. For a quick little hack it seems to be working well.

I'll print up some more and follow up with my IM's.

Thanks for everyones feedback.
 

duncsuss

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Looks pretty good - I sometimes get chatter like that using my "real" collet set, once there is more than 3" protruding from the chuck it's really easy to get vibrations at the free end.
 

NT_2112

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Quick update. I have printed the 1st round in Grey PLA. Now I am printing a set of them in Blue ABS. I think it might be a good test to compare and contrast how PLA filament holds up vs ABS filament. I will be sending both types to the beta testers. The colors are random BTW, just what colors I had for PLA and ABS right now. :)
 

NT_2112

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Hi all.

Printing was a little trickier than I expected, even more so for the .75” version.

Some screenshots to show what I mean:

colletstesting - 6.jpg

The walls get really thin with the ,75 version. The blue ABS filament seems to have an issue on my 3d printer. The collet won’t stay in one piece. I guess it’s still usable if you hold the sections together as you put collet in the chuck.

The grey and the green PLA seem to work decently with the green PLA giving the best results at a printing resolution of .12mm per layer.

The hardest past was figuring out the best support structure to use. When 3d printing an item you have to have the printer print support under over hanging areas. The down side is that the supports can be hard to remove.

Screen Shot 2020-11-23 at 8.28.45 PM.jpgScreen Shot 2020-11-23 at 8.29.29 PM.jpgScreen Shot 2020-11-23 at 8.29.53 PM.jpgScreen Shot 2020-11-23 at 8.30.42 PM.jpg

The teal area are the supports it will print. The other two images are cross sections looking down.



You can see an example of what happens when you don’t use supports properly, the area around the top rim of the collet gets stringy and falls apart.

colletstesting - 5.jpgcolletstesting - 4.jpg




colletstesting - 1.jpgcolletstesting - 2.jpgcolletstesting - 3.jpgcolletstesting - 6.jpgcolletstesting - 7.jpgcolletstesting - 9.jpgcolletstesting - 12.jpg


So now I have a .50 and .75 collet ready to be tested.

BTW, the final settings of .12mm layer height with 100% infill cause each collet to take about 4.5 hours to print. And you can only print one collet at a time. :-(

Not sure the cheapest way to mail. I will need to get boxes, should I use priority mail small boxes? Thoughts?
 

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duncsuss

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Wow - you definitely get an A-plus for perseverance!

If the total weight is 1 pound or less, Priority Mail from Rochester, NY to Wilmington, MA is only $8.00 - Small Flat Rate Boxes are $8.30.

(Either way is fine with me.)

Thanks!
 

NT_2112

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The first round went out to the beta testers. My thanks for being patient. In the process of selling my house and I'm a little disorganized over here. :)
 
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