3D printed DZ-2500C cover with dwarf signal (rotatable)

That's neat; something I may be interested in for some of my 50 or so DZ-2500s.  I have a couple of engines that go over the edge of my DZ-2500s.  Did you take clearance from the engines/cars into consideration, such as platform steps? 

The top has a thickness of  .063" or about 1/16 that fits tight to the top  and sides of the DZ-2500; the enclosure has to have some thickness.  The only engines I have had issues with the DZs are the triplex's  wheel rods  and the ES44ACs but that was for the DZ-1000s that ride higher.

I have not had an issue with the height of the DZ-2500s; which cars or engines are an issue for you?

I'm looking forward to seeing it materialise, Alan. 

Still have a few tweaks to do. The signal head will fit a standard bi-color LED for those who want to wire it into the switch motor. When complete the model will be available on Shapeways or if you have a 3D laser printer I'll send you the .stl file.

This was made on 123Design.

I also added an "operator port" on each side of the head, so that the operator can see the signal's color from each side without looking straight on the signal.

The back is open as an aid to wiring ( you can fit up to 4 -30ga wires up the shaft ) but I have back covers for the head and base electrical box that snap in place.

Is 123Design 'easy' to learn and use? I try to follow your 3d printing posts and I must say that your drawings look like you have been doing this for many years, Very Nice!!

Also very nice of you to post to Shapeways and also share your creations with other forum members.

Allen.. Another good looking design. What would the estimated cost from Shapeways?

123Design is free and easy to learn.

It part of the Autocad group of modelling programs.

Until I load it up on Shapeways I can't tell. Also it depends on how many I set up like 12 at a time.

So why not just Repeal the DZ-2500 top And Replace with a new top with a dwarf signal bi-color LED wired to the two DZ- 2500 LEDs?

AlanRail posted:

The top has a thickness of  .063" or about 1/16 that fits tight to the top  and sides of the DZ-2500; the enclosure has to have some thickness.  The only engines I have had issues with the DZs are the triplex's  wheel rods  and the ES44ACs but that was for the DZ-1000s that ride higher.

I have not had an issue with the height of the DZ-2500s; which cars or engines are an issue for you?

 

 

Alan,

Sorry for the delay in getting back to you; needed to take some pictures. 

All pictures were taken on the diverging leg of a Ross O-72 switch.

First two pictures are of my Weaver Passenger Shark pilot.

Third picture is of my Lionel Y3 pilot.  The Y3 is small for an articulated engine.  A Big Boy will overhang more.

Last two pictures are of the MTH PRR Q2 Duplex.  The first one is the front of the engine, and the 2nd one is the edge of the cab which overhangs more than the front.  There is less than 1/2 inch clearance.

Anyway, this was my concern with mounting anything on top of the switch motor.

Weaver Passenger Shark

Lionel Y3

MTH PRR Q2 Duplex

Ron

I see your pain.

What DZ would tell you is to move the machine to the other side of the switch or flip so the it is on the straight part of the turnout.

any reason why you cant flip it?

I don't think flipping it will do any good; the engine will still be on the curve section of the switch.  Moving it to the other side may have another set of issues with my 21" cars.  When I get the chance, I'll try other positions and let you know.

Alan, 

Great idea... because I frequently have trouble seeing the DZ switch machine LED's with the ambient layout lighting.

My son recently purchased a printer and I am pretty sure he's using 123Design...  When you're done tweaking the design could you send me the .stl file ? 

I'd like to have him print a few prototypes so I could see if they'll work on my layout... I am using mostly Ross Regular 11 degree switches and a few 0120/096 curved switches so there may not be any overhang issues.   Thanks 

ok  

I just finished printing the DZ-2500 switch cover. Its curing

 

 

 

 

Alan...How long to print each assembly? Does the printing software create the supporting structure or is it part of Cad123?

When models are put up on Shapeways does the final cost include a mark up for your well deserved effort.?

Does the signal base separate from the the cover portion ? If it does this might provide a solution for those overhang problems encountered if the user desires to use multi color LED's.

After looking at some of the rail related products offered on Shapeways, your designs are far more detailed than what is presented vs the part cost.

Great looking design.  

Gerry

Another possibility you might design an optional item  to mount the signal base at track level which would  provides a "tube or tunnel" for the fibre optics to connect to module  cover. Just a thought.

Still tweaking  latest is;

Made the finger button hole smaller; recessed the attachment screw holes in front; redesigned the target head so it was circular. increased the thickness of the hinges for the back cover plate; recessed the front underside so that the Dz-2500 snaps in.

Gerry

1.How long to print each assembly? 4 of them took 9 HOURS at 50mu(micron) resolution.  Double that,if I went with 25mu

2.Does the printing software create the supporting structure  YES but I readjust it so that a support point is not located at weak part of the print.When you use a hand cutter to cut the supports there is a "backward" force that can break small parts. The supports narrow at the tip to 0.4mm so most easily snap off by hand.

3 When models are put up on Shapeways does the final cost include a mark up for your well deserved effort.?     No, I am making these model to give back for all I have learned and used on OGRR.

4. Does the signal base separate from the the cover portion ? No, it rotates about its axis but could be removed by breaking away the underside round clip.

5.  If it does this might provide a solution for those overhang problems encountered if the user desires to use multi color LED's. You can insert a standard LED; the size is the same that Custom Signals uses.

After looking at some of the rail related products offered on Shapeways, your designs are far more detailed than what is presented vs the part cost.Great looking design.  

THANKS.

Another possibility you might design an optional item  to mount the signal base at track level which would  provides a "tube or tunnel" for the fibre optics to connect to module  cover. Just a thought.  Not sure what you mean. Can you email a picture?

Ok, just went to shapeways, never heard of it before.  Is your there yet?  Did a search and did not pop up, but a lot of things popped up.  Will have to try it on my pc, not just my iPad.

thanks

not yet on shapeways still tweaking

Alan,

Great work. This really shows the advantage of 3D printing to solve problems, create new designs, and totally avoid what would be excessive tooling costs. I'd b interested in seeing your final solution. You can e-mail me at drzander@aol.com.

Allan, Your design is coming along fine and looking real good.

You said before that the printing program creates the support structure, What purpose does the angle of the structure serve?

My signal bridge is complete and is installed with Pensey 7 light position targets functioning as intended. I just have to solve a mechanical problem with an associated crossover and I'll be able to get back to making some ground mounted mast signals i have planned.

Gerry