3D Printed HuCard Case Development (NOW AVAILABLE!)

[PCEngineFX]

So after learning about a few people that posted creating replacement HuCard cases, I've decided to work on my own version as well.  The purpose of this project is to:

1. Teach myself how to 3D model an object from the real world
2. See if a HuCard case can be 3D printed
3. Use the finished printed HuCard case to replace old/broken HuCard cases

Here is a shot of how much of the case I have modeled so far:



I almost have the proper size of the case down to exact dimensions but it's slow going as I tweak one setting, then I have to re-print which takes about 3hrs....but it is coming along nicely.  After the case is done, I'll work on the plastic arm and the borders for where the HuCard will sit.

I have no plans to mass-produce this model (no injection molding) but I may offer to print this up to people if it turns out good....too early to say right now.

11/17/14 UPDATE
Case model is complete - pricing/bundles to be posted next.

11/18/14 UPDATE
Due to a color density issue with new spool of filament that just came in, pricing/bundle details will be delayed.  Can't estimate when this will be resolved at this time.

12/12/14 UPDATE
Well I had hoped to take orders before the holiday but looks like this won't happen for multiple reasons:
- I will be purchasing a 2nd 3D printer in the next few weeks which will not only be at least 2x faster, but will also give me better print quality.
- I will be on vacation starting the 23rd, so nothing will be printed till after the 6th anyway.

Once I get the new 3D printer, I'll evaluate the print of the case, make any tweaks (if needed) and start printing cases en masse, which at that time ordering details will be provided.

1/7/15 UPDATE
Just waiting for my new 3D printer to arrive...once put together and configured, I'll then be able to re-print the case and do any re-tweaking to the design (if needed) before going into full production.

1/27/15 UPDATE
New MakerGear M2 printer has arrived and is still being broken in.  Not getting the surface finish I want yet from the printer so still in the tweaking stage.  No ETA yet until I can get the surface finish that I expect.

2/11/15 UPDATE
Print quality out of my new 3D printer is finally where I want it so one issue down - now I'm back to putting the finishing touches to the model and verifying that it fits correctly with the top case.....

2/18/15 UPDATE
Spending some extra time right now to find ways to cut down on print times for the case (takes about 2h45m currently).  I think I can cut this down by 30-45mins without sacrificing the quality of the finish or changing the print resolution but will require a few extra days of testing.  At the same time I'm tweaking the model to tighten up tolerances for when the top case is attached.

2/21/15 UPDATE
I'm happy to announce that I have completed the final tweaking/fitting phase of the model and so far have 3 fully assembled HuCard cases!  After I get a few more done I'll then be finalizing ordering details, taking photos/videos and all that good stuff.....we're close!

3/1/15 UPDATE
The HuCard 3DCase is now available here: https://www.pcengine-fx.com/forums/index.php?topic=18661.0

[cjameslv]

Very cool! So once you have it printing exactly how you want it, then you submit it to somewhere to get printed on a larger scale? Or do you just plan to make them on your printer?

[PCEngineFX]

Very cool! So once you have it printing exactly how you want it, then you submit it to somewhere to get printed on a larger scale? Or do you just plan to make them on your printer?

I'm exploring various options - can't say one way or another right now what I will be doing quite yet until I get the model to print right.

[cr8zykuban0]

please make this dream a reality! tgat is really cool that you are looking into making these!  hope everything goes well in your project.

[HailingTheThings]

Pretty sure jelloslug looked into this and it turned out to be too expensive. If your goal is simply learning how to model along the way to successfully creating a 1:1 case, though, should prove to be a fun, little experience.

<3

[jelloslug]

If you want it I can send you my model. I have had it printed before and it's a bit pricy.

[NecroPhile]

Neato.  I'd like to see how this turns out in terms of fitment, finish, durability, flavor, etc.

2. See if a HuCard case can be 3D printed

You've seen Atlantean, right? 

[mitsuman]

This is awesome! I have been fascinated with 3D printing for years. It is so cool to see it start to be used more and more.

Aren't there three versions of the cases? One with nothing (like what you have modeled in your 3d program), one like jelloslug shows, and one with just the "box" part in the middle?

[PCEngineFX]

jelloslug: That would be cool if you could send over your model - please email me at aaron.nanto@outlook.com.

Neato.  I'd like to see how this turns out in terms of fitment, finish, durability, flavor, etc.

2. See if a HuCard case can be 3D printed

You've seen Atlantean, right? 

LOL...yes, but I've not received my copy in person yet so I'm not sure exactly how they modeled it.  They also are using a different model 3D printer than mine.

I'm going to keep with the 3D printed route for replicating this case (again, no injection molding) so while it won't be as exact as the originals in color or build quality, it will be perfectly adequate to use for your loose Hu's or as replacements for broken/old cases.

[CrackTiger]

People attempting to produce new HuCard cases usually say it's too expensive, but rarely get into specifics.

I would be happy to pay $5 per case and am perfectly fine with the simple PC Engine style ones, without the arm holding the HuCard.

[NecroPhile]

LOL...yes, but I've not received my copy in person yet so I'm not sure exactly how they modeled it.

There's is a different breed anyways - shaped like a early, black huey tray but inserted into a standard jewel case like the later, white huey trays.

People attempting to produce new HuCard cases usually say it's too expensive, but rarely get into specifics.

Professionally 3D printed is something crazy like $40 each.  Injection molded is $5000+ to have the mold made, and not many are willing to pony up that kind of cash when they know that even at $5 each it'd take years to sell enough to break even (if ever).

[PCEngineFX]

Injection molding is crazy expensive, plus you have to order a minimum (10,000 units generally) so you also need somewhere to store all of those units as well.

[jelloslug]

People attempting to produce new HuCard cases usually say it's too expensive, but rarely get into specifics.

I would be happy to pay $5 per case and am perfectly fine with the simple PC Engine style ones, without the arm holding the HuCard.

Right now at Shapeways an exact duplicate of the Turbografx style back shell costs $34.77 (plus shipping) made out of the white material that I use for the parts that I'm printing.  To print it out of a higher resolution material to get it "perfect" costs $115.91 (plus shipping).
Here is a back case with a separate clip that I had printed a while back out of the high res material.

[jelloslug]

Professionally 3D printed is something crazy like $40 each.  Injection molded is $5000+ to have the mold made, and not many are willing to pony up that kind of cash when they know that even at $5 each it'd take years to sell enough to break even (if ever).

When I was trying to get the back case made even in China the mold was $7500.  The cheapest North American producer I found wanted $11000 for the back case mold and most of them wanted $20k for the mold.

[OldMan]

The cheapest North American producer I found wanted $11000 for the back case mold and most of them wanted $20k for the mold.

...which is why I was looking at a generic square mold with silicone molding compund.
Now if I could just find a nice, cheap injection machine....

[jelloslug]

The cheapest North American producer I found wanted $11000 for the back case mold and most of them wanted $20k for the mold.

...which is why I was looking at a generic square mold with silicone molding compund.
Now if I could just find a nice, cheap injection machine....

http://www.mediummachinery.com/

[OldMan]

http://www .mediummachinery. com/

Cheap being under <$500 . I didn't see a price there, but with a $100 discount, I'm betting its still out of my price range

I was looking at a drill-press style one, but the shot size was too small for a plate

But if one of you guys wants to pick this project up....
...maybe the next game will some with a nice molded tray.

[NecroPhile]

I didn't see a price there...

$2,887 + $92 shipping

No lube.

[jelloslug]

http://www .mediummachinery. com/

Cheap being under <$500 . I didn't see a price there, but with a $100 discount, I'm betting its still out of my price range

I was looking at a drill-press style one, but the shot size was too small for a plate

But if one of you guys wants to pick this project up....
...maybe the next game will some with a nice molded tray.

Be aware that a large, flat part like a tray is most likely going to need a heated mold or you will most likely get a short shot every time.

[PCEngineFX]

I think we can all agree that no matter how you go about it, it isn't cheap.

[jelloslug]

I think we can all agree that no matter how you go about it, it isn't cheap.

Yea, that's why I got as far as printing a prototype and hit the money wall.

[PCEngineFX]

Small update - need to resolve issue with the print warping on the build plate.  The case has so much surface area that there are some warp issues on the thicker end of the model.  Nothing I've not already had experience with before.

[Mathius]

This is sweet! I can't offer any expertise but will gladly be cheerleading on the sidelines.

[jelloslug]

Small update - need to resolve issue with the print warping on the build plate.  The case has so much surface area that there are some warp issues on the thicker end of the model.  Nothing I've not already had experience with before.

Can you heat the chamber on your printer?

[PCEngineFX]

Small update - need to resolve issue with the print warping on the build plate.  The case has so much surface area that there are some warp issues on the thicker end of the model.  Nothing I've not already had experience with before.

Can you heat the chamber on your printer?

I have a heated build plate, but not a sealed chamber.  I just added the hollow rectangular sections to the spine area so I'm guessing that will fix the issue.

[PCEngineFX]

I think the warping has been solved - ended up upping the build plate temp by 10 degrees C and last 2 prints not warping any longer.

Doing some final tweaks to the base model for exact sizing with the HuCard top case and adding a few more details to the design before moving on to finally modeling the area where the HuCard will sit.

[PCEngineFX]

Everything is fitting nicely now - current stage of modeling/print/fit-testing:

[Medic_wheat]

My loose hu cards thank you

My wallet not so much

[PCEngineFX]

Not failure, but progress.

[PCEngineFX]

STILL tweaking/fixing fit issues with top case but am really close to finishing.  Modeled HuCard case arm and now in process of fitting both pieces.

Final print times:
HuCard Arm: ~10mins
HuCard Case: ~2h30mins

(below, using timer to alert me when prints are done)


The design of my case will be extremely close to the original, with minor differences to facilitate faster 3D printing.......more to come.....

[cr8zykuban0]

Not failure, but progress.

practice makes perfection!

[Medic_wheat]

Not failure, but progress.

practice makes perfection!

Just like the bes side trash when I was a teen. Only it didn't have 3D printed cases inside. 

[esteban]

Not failure, but progress.

practice makes perfection!

Just like the bes side trash when I was a teen. Only it didn't have 3D printed cases inside. 

how so? Lots of soiled paper tissues?

Lots of teenage dreams in the trash.

[PCEngineFX]

Just an FYI, those soiled paper towels were used to apply hairspray to my 3D printer build plate

[HailingTheThings]

Just an FYI, those soiled paper towels were used to apply hairspray to my 3D printer build plate

I've never heard that euphemism before.... ouch!

Which is the build plate, the beans or the frank? lol

[jelloslug]

Just an FYI, those soiled paper towels were used to apply hairspray to my 3D printer build plate

Suuuuuurrrrre they were.  (wink, wink)

[PCEngineFX]

Jackie Chan finally has a proper home.




My 3D printed HuCard case is finally done.  Will be posting up ordering details most likely this week.

[HailingTheThings]

Jackie Chan finally has a proper home.

My 3D printed HuCard case is finally done.  Will be posting up ordering details most likely this week.

Congratulations!

Also, you're kidding about selling these, right? lol

[NecroPhile]

Mmm, that looks sexy.  How durable is the plastic compared to the originals, and does the plastic self-lubricate / outgas (causing label issues)?

[Mathius]

Woah nice!

[cjameslv]

LOL...yes, but I've not received my copy in person yet so I'm not sure exactly how they modeled it.

There's is a different breed anyways - shaped like a early, black huey tray but inserted into a standard jewel case like the later, white huey trays.

People attempting to produce new HuCard cases usually say it's too expensive, but rarely get into specifics.

Professionally 3D printed is something crazy like $40 each.  Injection molded is $5000+ to have the mold made, and not many are willing to pony up that kind of cash when they know that even at $5 each it'd take years to sell enough to break even (if ever).

Ever heard of kickstarter?

[PCEngineFX]

Jackie Chan finally has a proper home.

My 3D printed HuCard case is finally done.  Will be posting up ordering details most likely this week.

Congratulations!

Also, you're kidding about selling these, right? lol

Thanks, and no I was not kidding.

Mmm, that looks sexy.  How durable is the plastic compared to the originals, and does the plastic self-lubricate / outgas (causing label issues)?

The one you see in the photo has 10% infill, and even then it is pretty strong.  As long as there isn't a big hit on print time, I may increase this to 15-20% to give it even stronger internal support (will be trying this tonight).  Just don't go bending the thing on purpose and it should be perfectly fine sitting on your shelf.

As far as self-lubricate/outgassing, I would guess that 3D printed objects don't have this issue since they are not perfectly sealed  (someone else can chime in about outgassing with 3D printed objects - I don't know for sure).

I'm most likely going to offer the case in small quantity bundles to make it worth my while - stay tuned.

[clackattack]

Awesome looking end-product there Pcefx! Glad someone was finally able to pull this off now! Weve been teased with talk and speculation of these for far too long. Count me in for a batch once you start taking orders

[esteban]

Jackie Chan.

[in99flames]

11/17/14 UPDATE
Case model is complete - pricing/bundles to be posted next.

This is great news!!

[Gentlegamer]

It's like we're living in the future!

[jelloslug]

Nice job!  I have been toying with the idea of making the clip and case one piece to speed up printing time and cut down on material.

[cjameslv]

I have to say that was a really fast drafting to final product timeline! Thanks for putting in the effort to get this done 

[PCEngineFX]

Due to a color density issue with new spool of filament that just came in, pricing/bundle details will be delayed.  Can't estimate when this will be resolved at this time.....sorry guys...was hoping to start orders this week

[Medic_wheat]

So. Is this something where we combine this with a upper cd clear case?