I changed my ignition switch from the typical keyed rotary ignition/starter to toggle switches and a pushbutton start.
The replacement switch panel was designed in a 3D CAD program (FreeCAD) in a 3D-printable format. I did rapid prototyping and printed multiple small test pieces to ensure the model files fit the components (keyways, anti-rotation flats, hole size, panel thickness, etc.) and went through a total of eight test panels before I was satisfied everything fit well.
The labels were inlaid 1 mm into the main panel body with a multicolor printer, but they could also be printed as raised lettering on a single-color printer with a manual filament change.
I experimented with different nozzle sizes (0.25 mm produces the most legible text), print surfaces (textured prints better than smooth/satin and looks more cosmetic), and materials (labels of glow-in-the-dark PLA/ASA had unsatisfactory contrast).
The original panel was designed in a 2D CAD program and drilled/filed by hand from 0.063-inch aluminum, with vinyl labels overlaid onto the aluminum. I didn’t have access to a service like SendCutSend when I built the plane, and it was frustrating and time-consuming to create a new subpanel only to find something didn’t mechanically fit and the panel had to be remade.
A new panel can be 3D printed in a couple of hours for pennies—much cheaper and quicker than creating a new aluminum panel manually or through a contract fabricator. The prototype 3 mm 3D-printed panel was 28 g (1 oz) lighter than the aluminum version (PETG, 15% infill), and the new switches were 110 g lighter than the old mechanical keyed switch.
The switch panel pictured was a PETG prototype, and the final version is flame-retardant ASA (more tolerant of UV light and heat). All told, the 3D-printed panel is cheaper, faster to produce, and lower in weight than an equivalent aluminum panel.
Thx Daniel….seems like there will be many applications where one can use a 3D printer to customize panels. When you put down your scapel, your got another career waiting! (I fly a Sportsman as well).
Did you mix nozzle sizes? .25mm for the text in white and .4mm for the black? Or both at .25mm?
I mixed nozzle sizes, but this can only be done with multi-tool printers. I found the letters were fuzzy with 0.25 mm letters and 0.4 mm infill around the letters; it prints better with 0.25 mm letters and infill. I can print the solid layers behind the text with a 0.6 mm nozzle to make it faster.
There are many multi-filament printers that change filaments, but are constrained to use the same nozzle for the entire print. I have a Prusa XL with five print heads and a tool-changer, but is cost-prohibitive for hobbyists. In this instance a multi-tool machine only improves print time – any single nozzle printer can print a panel with a fine nozzle, it will just take longer.
Thanks for sharing. Beautiful work..!