Trying photo-etching: A tower crane (among other things...)

[Madsing]

I need a tower crane for the construction site on my Yūkari layout. I have purchased the MID BD-01 (https://www.1999.co.jp/eng/10139589) but I was disappointed by the lack of details. After reading the Yūrakuchō thread, I decided to try photo-etching and design a better model. I contacted a couple of companies close to where I live (Singapore) but none of them would just make a single piece. I am now planning to work with the same company as @Kamome442, PPD Ltd as they provide a lot of details on their web site. The smaller sheet size that can be manufactured is 300x150mm so I'll probably have enough space for multiple projects on a single sheet.

 

I have decided to model the JCL015II Tower crane as technical drawings are easily available here: https://www.sangyo-leasing.co.jp/products/climbingcrane/JCL015II.html. It's also the smallest tower crane I have found. I am starting drawing the etching file. I will probably use 0.125mm stainless steel. The smallest detail that can be etched is 0.18mm.

 

 

@Kamome442, can I ask you a question? In the drawing below, large divisions are 1mm, small divisions are 0.1mm. The width of the blue line (that will be half-etched on the bottom (inner) side) is 0.2mm. Is it a good idea to use that construction to fold the sheet along the line? Thank you!

 

Marc

 

 

[Kamome442]

Hi @Madsing, great to see this project is taking shape! You will get a fantastic level of detail with an etched boom. That construction fold will work perfectly, what I will say is when you fold it the metal will try to bend where there is least resistance. The will likely be the open areas with the cross-bracing. I would recommend using an etch folding tool or a creating some kind of jig to prevent any deforming.

[Madsing]

Thank you very much @Kamome442. I will report on the progress.

[cteno4]

Yeah that long fold will be a challenge. Clamping the piece between two thicker steel or aluminum rulers (or pieces of steel stock with nice sharp edges) to the table top with the edge right at the fold line will help. Then stick another ruler under the piece hanging out and butt up against the bottom ruler and use it to fold the part hanging out. This should force the bend along your weakened bend line nice and straight and not warp any of your cross braces during bending. I do this for longer cardstock folds. For small cardstock and etched metal I use my little etched folding tools but those only handle up to 2-3”. I’ve always meant to make my own long bending brake by just drilling a couple of hole thru two thick rulers at the ends and then using a bolt and knob to make them clamp down together easily to a base board.

 

jeff

[Madsing]

Yes, I understand that will be a challenge. I googled “photo etched bending tool” and found many tools that could help (some of them expensive). This guy explains how to make one, exactly what you said (Jeff):

 

 

Alternatively, I could change the design to avoid that long folding line, but then I’ll have to attach the four sides of the beam together, and that may not be easier…

[cteno4]

For little bits like this one does there are a bunch of nicely done ones out there for $20-50 that are super handy for small folds and details. These usually just have a single big knob to clamp fast and you use a thin piece of metal to be your folding bar (or a dulled safety razor).
 

there was a great little brake press (that was made from etched metal!) that was great for longer stuff up to like 10cm, but it’s sadly oop these days.

 

it’s for those long folds you need to roll your own. Just think of the above but longer. When folding press down on the center to the top bar while you fold up with the ruler you slip under the fold piece. I’ve been lazy and just use 2 clamps on the bench top instead of the bolts and wood base. With paper craft (most of the long folds I do) I don’t even clamp the bars around the stock. I just put two little clamps on the edge of the bench to push the 2 rulers up against (to keep them aligned on the fold edge and like paper up on fold line, push done and use another ruler to do the fold from under. Every time I do this (and while writing this) I think I should spend an hour and make a nice one and then think, ok next time! [repeat]
 

I actually find I do the majority of my small folds with the variety of needle nose and flat nose pliers I have, quick and easy for me but others love the folding tools for most folds. But I go to the folding tool when it’s a longer fold or a long piece hanging out that does not work well in pliers or I can maneuver the pliers in right. I’ve seen some etched metal kits that give you a whole folding sequence as there is only one way to get it folded up right! 
 

if you have excess space around the edge of your etch put in some long test folds you can practice on before doing the crane
 

jeff

[cteno4]

So I found the etched metal mini brake I was talking about, I had spaced in its name. It’s the PhotoFold by ParaGrafix. It’s oos right now from the manufacturer paragrafix, but some shops have it. Love this little guy.

 

https://www.culttvmanshop.com/PhotoFold-Photoetch-Bending-Tool-from-Paragrafix_p_2229.html

 

jeff

[Madsing]

Oh! This one looks nice. It’s long and the part that helps bending is attached. 

Edited February 2, 2022 by Madsing
Typo

[cteno4]

Yeah it’s super simple. The top plate just slides into the little side flap notches so easy to pop piece in and place the top piece on press together and fold. I usually just use my fingers to hold things in place and on longer bits I put on the edge of the table and press down with a few fingers. You can use a binder clamp, but that’s just fiddly and can slide things around a little. Works great for papercraft folding as well. It’s a perfect bending brake which are super fun to work on with big metal projects. Really is a neat design.

 

jeff

[Madsing]

Update on this project.

I am being carried away, not by a moonlight shadow, but by 3D design. Since the sheet that will be photo-etched will be 300x150mm (that's the smallest size), I have started thinking about other things that I could design. Then I thought it would be good to design these objects in 3D. I started playing with Autodesk Fusion 360 (I have a free license for personal use) and its Sheet Metal module. With this module, Fusion 360 allows you to design objects in 3D, then it unfolds them to generate the flat pattern that will be photo-etched. It's not always easy, but I find it quite cool. I have spent the last two (three???) weeks learning and playing with that. It's a long time, but I want to get more familiar with 3D design anyway as I plan to do more 3D printing in the future. I now have 3D models of the tower crane (the initial project), maintenance platforms for my EMU maintenance terminal and a beginning of warren truss catenary.

 

 

 

[cteno4]

Super cool! Those are going to be great. Very useful cad tool.

 

jeff

[gavino200]

These are really awesome!! Someday I'd love to try my hand at this stuff.

[Madsing]

That's what the design file looks like. I have now sent it for manufacturing, which will take 3~4 weeks, plus shipping.

I keep my fingers crossed 😀

 

 

[cteno4]

Awesome sauce!

 

jeff

[Madsing]

I am really anxious to see how this will go. I have no doubt that the etching of the stainless steel sheet will be perfect, but I really do not know if these things that I have drawn will be easy to assemble, and how they will look like. That's really a first test. Anyway, no pressure, if I have made too many mistakes I will try again 😀

[Kiha66]

Wow, incredible work!  I'm certainly interested in seeing how these turn out.  How much does a sheet cost, typically?

[Madsing]

I am working with this company: http://ppdltd.com/

They have been recommended by @Kamome442
I looked for other companies closer to my place but PPD have a lot of information and tips available from their web site so I really felt safer working with them. Their pricing is detailed here: http://ppdltd.com/costs.html

I have paid exactly what was listed on their web site. £30 setup cost + £13.50 process cost + shipment.

As the sheet is close to the minimum size, I have packed as many things as possible on it. Three catenaries with 8 catenary poles, 5 maintenance platforms, a tower crane, a few palettes, 120 cm of different types of gutters, and a few other small things.

[Madsing]

No real, but only virtual progress these last weeks. While the parts for the tower crane are being photo-etched, I am improving my 3D design skills, learning how to use Autodesk Fusion 360. That's a whole world in itself, so I am focusing on design for manufacturing, to help with photo-etched and 3D printed parts.

 

This is the space I have for the construction zone. It is stuck between two curved tracks, so there will be a "curved building" with scaffolding and the crane next to it.

 

 

These are my inspiration photos for the building (photos taken in July 2019, a building that was under construction next to where I was working in Shin-Yokohama).

 

 

And finally a recent rendering of the crane next to the scaffolding. You can see a small servo motor right below the crane, as I will try to animate it.

 

 

Edited April 10, 2022 by Madsing

[Madsing]

It's here. I am so excited. It looks so perfect, so detailed!

I have to savor this moment, until I start to cut it and find my mistakes 🤣

 

[Kamome442]

Looking good!

[cteno4]

Wow looks great!

 

jeff

[Madsing]

Things start to take shape...

 

The top and beams of the tower crane

 

A steel maintenance platform

 

And (plastic) palettes

[inobu]

Platform is nice......

 

Inobu

[cteno4]

Ooooh looking very nice! Especially for your first whack at it!

 

cheers

 

jeff

[gavino200]

Awesome!