Bending Steel With Plastic Tools

I've been wondering if 3D printed tools could possibly bend steel. It seemed possible unlikely. I designed and printed several tools which are used on a hydraulic press to bend and form steel sheet metal. This particular tool could be made by CNC machining the tools from metal but 3D printing it is much faster and easier.
These videos usually take a ton of work and a lot of money in tools and materials. I've made a patreon if you're interested in supporting the creation of these projects: / stuffmadehere
If you're interested here's some of the tools that I use in this video:
Pneumatic jack conversion for my 20 ton press: amzn.to/3ajft6j
Hypertherm powermax 45xp with machine torch: amzn.to/2zfoyAv
Small machinist square. Cheap but useful: amzn.to/2XK6I2N

[@court2379]

I have to laugh at the $50 in resin used to fix a $30 saw, but obviously that wasn't the point. Great demonstration, I wouldn't have thought it would hold up as well as it did.

[@FlybyJunkie]

We build $500,000 cells to make $0.27 taser darts for $200 guns 😉

[@computername]

Why just buy a tool when you can spend twice the amount of money to try and make one yourself - it makes you appreciate the real tool that you buy in the end so much.

[@dinosoarskill17]

is sla that expensive?

[@xConundrumx]

I get what you are saying, but if you can re-use the mold for multiple copies ... Admittedly this particular item might not be the best example for that.

[@JamesLee-sw6ss]

@@xConundrumx Not sure how many times... Exploding dies were a theme :D

[@FlybyJunkie]

As a Tool and Die maker it was interesting to see you work through this, impressive what you were able to do with 'plastic', really

[@charadremur333]

Resin.

[@dimitrispapadakis2122]

chara dremur that is the reason he put air quotes

[@ataraxic89]

@@charadremur333what do you think resin is?

[@Phelan666]

@@charadremur333 Rosin.

[@okuno54]

@@Phelan666 Rosin is a solidified resin from which the volatile terpenes have been removed by distillation; I don't know of any 3d printing process which uses or produces such materials.

[@UpsetCuzzy]

His dads such a genius. Creates a genius with the help of his wife, which 30 years later fixes his tools for him. Master of all plot twists

[@weeb3277]

His dad's wife 3D printed a genius.

[@lorenzothepasta2820]

@esp ele wha

[@melissa6470]

It was is master plan all along

[@jasonhance9088]

This is a common issue with forming dies. You were on to something when you said the die was in tension. To overcome this issue you can press fit the brittle material like tool steel, carbide or plastic into an outer ring. The key is to preload the die cavity further than it would naturally stretch during the bending operation. This prevents the tool material from goin into tension. The best way to do this is to add some draft angle to the die insert and make the opposite shape in the outer ring that is smaller by the amount of compression you need. You would then press the insert into the ring to achieve the interference desired. If you get it right the die will not split. You would then be limited by the compressive strength of your tool material.

[@Stagg369]

I love science man. I just works, and when you see it, in the moment. That we are slowly becoming the masters of everything (if we don't blow ourselves up before then), it boggles my mind

[@kieronscully1161]

That's a great explanation, thank you for sharing fantastic info and insight like this!

[@gracefool]

@@Stagg369 the problem is we're not masters of ourselves, so the blowing ourselves up part is inevitable. More people were killed last century than the previous 19 combined.

[@ruukinen]

@@gracefool A total of *50 billion people lived between 0-1900 compared to a total of 10 billion between 1900-2000. I question your assertion. * Estimated

[@gracefool]

@@ruukinen Sorry I should've said "killed in war". I don't know about killed all up. And of course the average person died younger.

[@NightFiire]

I’m watching all of your videos and I have seen the evolution from how you film them and I must say the newer videos are much more attention holding and entertaining while maintaining all of the cool machining and knowledge. I’m glad you read and take consideration into comments from your viewers. It has made viewing even more enjoyable =)

[@sam123rocks]

this is so true, i just came back to this one after seeing it in my recommended. His new stuff is crazy different. He really upped his game with the editing

[@leoirias3506]

Yeah and not only the editing part, the way he handles himself in the videos is so much better. And way funnier too haha

[@iangomes]

This channel is awesome. I appreciate you going back and trying it without the machined part, too. That attention to detail really makes the channel great.

[@pacman10182]

"somehow lost the blade guard" "lost"

[@namAehT]

Kind of amazing how far your videos have come in these past two years. I'd love to see some "smaller" more exploratory videos like these two sheet metal forming videos in addition to the "large and strange" project videos.

[@chromosundrift]

Quick audio suggestion: I've noticed in many of your videos that your compressor successfully cuts in whenever you drop a part on the bench to avoid an overly loud bang, however the release time is quite long so your voice is too soft for a moment after each time you do this. If you reduce the release time by 100-200 ms it should fix this. Additionally prepend a high pass filter with a well chosen low cutoff frequency before the compressor, and you will have less power in the bang of a dropped part which will help keep that out of your final audio without removing too many low frequency harmonics from your voice or the other interesting sound you want to keep in videos like these.

[@pacmop]

I like your funny words magic man.

[@stroopwafelfalafel]

I've been looking into getting better at basic audio editing. Got anymore tips?

[@cellularmitosis2]

Thanks for sharing this! Dabbling in compression myself.

[@bikefarmtaiwan1800]

Made some bending and punching dies for a project a few years back- incredibly satisfying. It is great to see what a fantastic job you have done with plastic forms. Love your plasma cutter

[@AlphaBobFloridaOverlord]

I greatly appreciate the time, the effort, and the expense of doing all these experiments and the fact that you’re sharing it with us! It looks like you’re working through the challenges in a very logical and efficient manner.

[@timothybishop8755]

I feel like a learned a lot in this video. Excited for part 2.

[@markgiles8527]

I am liking all the creativity I am seeing on KZbin. Well done, bro.

[@patrickchristie82]

I’ve been looking for something like this for a while. Happy to find this. Subscribed. I’m planning to try something like this with PETG on an FDM printer. I learned some things here. Looking forward to future videos.

[@joell439]

I watched the whole thing because every one of your carefully selected words are both entertaining and informative. What a great channel. 👍👍

[@MrSlaughtematic]

If you do the powder coating in house, I'd love to see a video on that

[@Z-Ack]

Is not hard , they actually make a kit to do it in your oven.. eastwood makes the powder and you statically charge the powder with a special gun and ground the part then bake on the powder in the oven... perty cool but couldnt be nearly as skookem as factory coated parts where theyre put in a kiln...

[@NigelTolley]

There's a few ways to do it. A coat of oil then "shake n' bake" would work for that small stuff. Or the hot air gun method.

[@unbelievabubble]

Most innovative use of 3d printer I've seen in a long time!

[@reallynothing6845]

Try searching for a KZbin buddy.

[@staalman1226]

@@reallynothing6845 He said " most innovative" not "weirdest"

[@unlink1649]

IMO that's what 3D printing is about. Making prototypes rapidly to test comcepts

[@betogonzalez5714]

Very excited to be another subscriber! Great content, as an engineer I enjoy these deeply

[@Cherokee913]

@Stuff Made Here Happy one year since your first KZbin video upload. Wishing you a very happy and successful decades to come of building, designing, programming and bringing enjoyment to millions. I will be following your KZbin career closely and permanently. Thanks for your hard work and excellent content. You're appreciated to infinity and beyond. Cheers

[@makingtechsense126]

Over 15 years ago I worked for a company that churned out millions of metal pieces per month. I learned a lot about punching and forming metals from pure observation of the manufacturing process. Metal forming has always fascinated me. Watching you do this with 3D printed dies is amazing.

[@RandomInsano2]

Excellent video! I’m a hobbiest and far from a machinist, but the fact that you vocalized the pressures involved and the reasons the dies broke really got me thinking. I learned a lot in 20 minutes! Keep it up.

[@NoName-zn1sb]

hobbyist

[@RandomInsano2]

@@NoName-zn1sb Thonks!

[@bjondersson]

@@NoName-zn1sbI think he meant he is hobbier than others, and thus hobbiest.

[@thenickdude]

Great project and really well presented!

[@mohammadomarchagani]

I am recent subscriber and I can FEEL the difference between his recent videos and this one and it is crazy how much he has grown as a content creator in this while because I love his recent videos with the little jokes and everything

[@karlfimm]

I've seen a number of people using 3d printed press brake tooling, but this is the first time I've seen printed forming tools like this. Very interesting.

[@user-njyzcip]

12:49 you missed a golden opportunity to say "that die has died"

[@Mrcaffinebean]

This was fun! I just subbed! Your approach to learning and teaching reminds me of Applied Science.

[@uziel25]

Starting a binge of all your videos liking videos as I go. Been watching you for years. Great videos. Thabk you for making them.

[@xavierolle]

Man, those kind if videos are absolutely gold! Awesome!

[@ChikitoPOWA]

Very nice and interesting, I'm looking forward for the next part!

[@FalseElysium]

@@capitalm417 yes it was

[@clayton_earl]

Bloody legend…

[@bestcodclips805]

U were the first of the first kaliin

[@cloudyeight]

Top notch video. Gained a sub. Keep doing what you're doing and you'll be at 1m subs in no time.

[@averyshaw2142]

looks like you might be right

[@MetalMario137]

Yeah, it literally took no time at all lol. As of 10-13-20 (6 months after OP), he's already at 1.07 mil!

[@bldjln3158]

@@MetalMario137 He’s gained 200,000 since your comment only six days ago!

[@MrMikkmokk]

This comment aged well.. 😎

[@jorgemiar]

9 months later and he's about to hit 2M

[@medyk3D]

Magnificent job. I like how determined you were to do it 'right'.

[@peterw1534]

That end result with powder coating looked amazing. Great job sir.

[@dingbattoast7446]

"Gives me that great feeling of instant gratification I'm seeking" The number of decisions I've made in my life for that very reason 🤣

[@Tachikomaster]

Nice idea and execution, also decent explaining, I like where this is going! Also, I think you and This old Tony have the same manicure studio :D

[@rodneypereira5518]

Great project, it shows the capabilities of resin printed moulds. Well done.

[@mhelmreich1]

The reason I watched this is because you have pretty much done something I want to try. I learned quite a bit from your success and failure. Keep up the good work.

[@alberthancock672]

This is awesome…hope your Dad appreciates the fix for the saws all

[@Birdman369]

After 2 years in eng, I can finally understand most of the terms Shane is referring to

[@CraigHollabaugh]

Very comprehensive, well presented and shows overcoming pitfalls. Excellent video.

[@StuffMadeHere]

Thanks! I'm glad you like it

[@jasonbeuke495]

50k subs in a few days!!! You deserve every single one!!! Keep up the awesome work💪🏻

[@FarmCraft101]

Awesome video. What material were you printing with? PLA? ABS?

[@shifty7739]

Looks like SLI printing in resin. Not sure.

[@atomix2559]

@@shifty7739 Yeah he says it's resin near the end of the video 19:35

[@LittleRainGames]

that is form labs tough resin well, the blue die was.

[@RegeraV8]

The grey one looks like tough 2000 form labs resin. It is resin for a SLA printer. I have one too and the prints are so much stronger than FDM prints

[@RegeraV8]

@@LittleRainGames i think the blue one is draft resin, my draft is blue at least and the layers seem quit high

[@justinlau6865]

Its amazing to see the progress of this channel in 11 months! The production value, the writing (!) and the projects have gotten really really good in a super short amount of time. I wonder how many subs this channel had in march 2020? 2m in Feb 2021

[@igorz3551]

2.4m March 3, 2021

[@OGbluetooth_]

Also, the memes

[@pire2]

3.58 M 1er January 2022

[@brucewilliams6292]

I love the tenacity and the idea. Great job. You have a subscriber.

[@bibekkarna01]

its fun to see how industry in Nepal doesn't have stuff you have and the knowledge is through the roof. keep up with the great work !

[@ameliabuns4058]

I love how injured your hands are. That's the maker life xD

[@Livlocalmartian]

Not really maker life, anybody that works hands on for a living has frequently injured fingers. My dad installs windows and doors, and he once brought me home the point of his finger pad and asked me to put it back on😂

[@agentsd3428]

@@Livlocalmartian no one asked for it

[@knucklefist8535]

Thank you. I hope your channel takes off! I've been toying with this concept in my head for a while, but I'm not an engineer. Seeing you put in action is a real inspiration. I want to make press formed metal panels (brass) for scale auto/rail modeling. Imagine a true to scale unibody or Monocoques made from 3D printed die press formed parts.

[@StuffMadeHere]

Brass would be a lot easier than steel. I tried to do this on hard mode with 16/18 gauge steel which is incredibly strong. No need to be an engineer to do this if you have 3D modeling skills. This could be done in blender or any other modeling packages.

[@brandontscheschlog]

Awesome! I just started watching your vids. Your one smart dude. Nice work man, look forward to seeing more

[@_DRMR_]

Subscribed. Your sheer determination was awesome to watch on this project. Looking at the press footage I'd say the main issues are aligning the downward force equally across the piece. What you said about multiple passes or stages of forming could definitely be the trick to get a square finish over all the bends.

[@veltro5659]

1 year of Chanel and 2 million subscribers... This guy is savage

[@CaiAllinx]

This so interesting, I know you couldn't work out every little detail but as someone who has worked at a company designing new machines and spending thousands upon thousands on tools and dies; This is super promising for reducing the cost of designing machinery. For a company moving into mass production, creating parts in this way is an absolute necessity and this could be a way to drastically reduce research and developments costs. Can I ask what resin and 3D printer you used for this process?

[@ExtantFrodo2]

Yes, if the plastic version even holds up for one pass of forming, you know you can make the same form in steel for mass production.

[@Brandon-zo9ly]

This. Replicating a replacement part for a cheap tool is not the end goal here. Being able, to for work or hobby, take something from an idea to forming metal is game changing.

[@decomposingman]

I’m just in awe at your genius.

[@carloseolvera8710]

For us makers the journey is as rewarding as the destiny. Yes, it may not be cost effective for one project, but what we learn will eventually pay dividends on future projects. This is a great teaching video by walking us through your thinking/solving process!

[@jamesatwood4433]

Has tormak, does not have color printer.

[@bmo14lax]

*helped create tormak

[@NoSubsWithContent]

9:11 "so i just kept on smashing to see if i would get anything out of it" Hehe you know what im gonna say but im not saying it

[@ExtantFrodo2]

"Squeeze him here and see if he passes another." (Monty Python something or other)

[@mikeygee4564]

Great vid. Loved the process. Subscribed. Keep it up!

[@tibfox]

Great demonstration and explaination of the issues and solutions. Very aprecciate this kind of content!

[@freemoviesforyou7090]

Am I gonna be the one to say it ok 0:00 legend was born

[@nobodyasked9047]

Yeah dude, probably the fastest growing channel I’ve seen. He’s gained 2.7 million subs in one year. Very impressive.

[@SiriusFuenmayor]

There are videos here on KZbin that make metal parts from 3D printed parts "lost pla casting", in the last one I saw the results where pretty good. You can use that to bend ticker parts

[@yolosubmarine]

Phe-friggin-nominal channel mate. Excellent work. Came across your videos after buying a 3x1.5m router. So inspirational.

[@someguydino6770]

Brilliant, innovative AND persistent = BRAVO!

[@David_11111]

$1000 dollars worth of engineering, to fix a $20 saw .... love it :)

[@adammetzger4182]

I probably would have bought a new one. Took the blade guard off and put it on the old one. Then returned the new one and them it was missing.

[@UnwrappingByMimiKoteng]

15:45 nice vise!

[@waynereid6147]

New sub! My daughter and I enjoy watching you make all your great ideas a reality, can't believe didn't come across your channel sooner regardless glad we did!. Keep up the great content!.

[@cwflemmer]

Great video. You have shown that using 3d printing to assist with more traditional methods of manufacturing is possible. I get more value by seeing the path to success, then just a success story. Keep it up, hope to see more videos like this....

[@gregjenkins5258]

"The printer wasn't available". You mean you didn't want to wait the eight hours it was going to take make a new one. Lol

[@Segphalt]

More likely: "I'm already 6 hours in on a different 40+ hour print and I'll be damned if I'm stopping it now when I can churn this out on the mill in 30 min."

[@rmyc]

3d magic Mike has done many 3d printed dies

[@stevenharpervw]

Well done, great video , and very easy to understand and follow

[@JoseMerino-gw6xd]

What you do is amazing really gets me excited to do something great

[@MakeStuff]

Can I use 3D printed parts to bend steel? > Machines the die anyway Half cheating or not, I'm digging the videos. Keep it up!

[@MakeTechPtyLtd]

Shared on 3d printing club Facebook group (36k members). -Ken

[@prestonradde6165]

was gonna wait to watch this video then couldn't find it, now it's time!!

[@amaarquadri]

Great video! I love how you showed the entire design process, errors included, and analyzed all of it. Very informative!

[@zero_gravity5861]

Makes massive, solid SLA parts. That’s it.

[@waywardhero1177]

LJTwiggy I was wondering if FDM would work better? A solid piece with properly annealed layers could do wonders. Plus it works to FDM’s strength

[@zero_gravity5861]

Exactly my point! It’s not like layer lines would get transferred to the part anyways. And when properly oriented, FDM would not only hold up to the vertical compressive force much better, but also be particularly well suited for the expansive force provided by the part while bending.

[@MultiMcgruber]

I'd be curious to see how an FDM material like PLA would stand up. Or if an intermediate forming stage would reduce the stress involved?

[@StuffMadeHere]

An intermediate stage should definitely reduce the stress. If I can't get this to work with a stronger material then that's next on my to-do list. This is often done in progressive die forming operations. PLA might survive at 100% infill. It's really soft but if you avoid super high local stresses it might work out.

[@citterly]

I've played around with this a little, ABS was fine with 0.065" aluminum. From what info i could find, i think the SLA resins are weaker. Great video, thx for sharing.

[@tinygaragefab]

@@StuffMadeHere I've seen it done and will do it myself with low infill (~10%, as open as possible) and filled with epoxy to make it much more solid.

[@Hunter-ym2kk]

just started to watch this vid.. i am a former engineer at Panasonic America. I worked on the cowling for the Boeing 777 Rolls Royce Engines, which is aluminum based metallurgy. The molecular work is the same for ferrous metals. Get the metal in a form where the molecules become fluid, and then move them to their max position, anneal the base metal, and repeat.. if you are doing all your work at STP, and do not ever anneal, you are "wrecking" the structures that you want saved for the final product. Ie.. it takes 20 process steps to move aluminum 1/4 of an inch, 3D. But, once you get there.. best possible product, which will not shear and fissure apart with micro vibrations.. love your stuff..

[@TulseLuper92]

Awesome post, thanks ever so much, I’m a new subscriber so happy to have run across your channel!

[@weldmaster80]

Next step, an ak bending jig lol

[@DasIllu]

Milling really is just 3D unprinting. :D

[@trevorthrift3121]

Very much enjoyed your video. Would love to see more on your vise break.

[@kylekowalczyk3437]

I wish I was friends with this guy, so many cool tools and so creative!!

[@zackjandali]

“Hopefully you enjoyed this. If you didn’t, I have no idea why are you still watching this” 😂😂😂

[@EcoMouseChannel]

You are 90% there to hydroforming. I'm pretty sure the 3D printing can be used as bucks and forming dies. But with the hydroforming techniques, the flowing medium supports the material all the way around. Giving you much crisper features. My favorite DIY version just uses a steel box and a rubber pad with the shop press. kzbin.info/www/bejne/rqiYqniDqKmriJo

[@regi3.1]

Wow man... You have lots of skill, patience, intelligence, time, and money.... And much more. HATS OFF MAN,! love n like all u r videos. Wish i could be like u.

[@EnsignLovell]

Hmm, never thought of this, awesome video!

[@mykalimba]

Moral of the story: you get what you pay for at Harbor Freight.

[@Finnspin_unicycles]

look at 3dmagicmike on instagram, he did some very succesfull sheetmetal forming with 3d printed dies.

[@cyanidetrece]

Beat me to it. @3d_magic_mike

[@chrischris8550]

A worthy video. Good work.

[@sebastiangregoroff3370]

Awesome ! Very interesting! Thanks for sharing

[@hemaangs3024]

Me {desperately trying to salvage a toxic relationship}: 9:14

[@fzigunov]

Thumbnail: "Made with 3D printed tools" 1:45 - Shows a giant plasma cutter

[@Daniel_Herrero]

es cierto, pasa con muchos videos, el titulo dice FACIL DE HACER, HAGALO UD MISMO HECHO EN CASA, POR SOLO 1 DDOLAR, Etc, luego termina ocupando una maquina industrial de $100000 para hacer una pieza que cuesta $1

[@Preso58]

Interesting concept. I'm keen to see more.

[@StuffMadeHere]

Thanks. There are so many things that I can imagine making with this. I have one project in the early stages of planning that should use this technique really well. Hope to share soon!

[@ColinTimmins]

This was a really good video, very inspiring...

[@Arek_R.]

So you used tens of hours and 30k+ of equipment to fix 10c part from a $20 powertool? Also how do you print such thick objects? With my cheap resin printer the part comes off the buildplate if it's thicker than 2mm...

[@Jerguu]

You missed the point of this entirely.

[@devonhansen1831]

I like the cut of your jig. A video on your 3D prints would be cool. They look like SLA unless I miss my guess. Keep up the awesomeness man. Your an inspiration.

[@JimOHalloran]

This video has shown up in my KZbin recommendations on and off for months now. It was only after watching your awesome collaboration with Dusty and checking out your channel further that I realised it was also one of yours. Not sure what that says about the power of celebrity vs the KZbin algorithm, but the algorithm knew me well enough to know I'd like it, still it took a celebrity endorsement to get me to actually watch it?? Anyway, I've watched most of the videos on your channel now and loved them all. Good stuff, the software engineer in me really appreciates your sense of humour.

[@samharrington8203]

This approach has incredible potential

[@stapes7344]

A legend was born

[@JB-yp6bd]

awesome work

[@bryans6455]

As someone who has 10 years in a sheetmetal fab shop I'm impressed!

[@MaxBrainDevices]

Great work with this