This Part is Impossible To Machine

[@chadmaurer4002]

"that's some big talk for someone who runs an electric band-saw" You guys kill me

[@trevorgoforth8963]

Don't encourage him! 😂

[@chadmaurer4002]

Great video BTW @@trevorgoforth8963

[@akronimm862]

Next time our wire guy gives me shit I’m using this line

[@eliasmarq007]

I fucken loved that statement

[@amarissimus29]

What else would a band-saw run on, exactly?

[@Sara-TOC]

It’s amazing to see how advanced manufacturing techniques contribute to the success of space missions.

[@seancollins9745]

I'm starting to think that might be part of the problem, is anyone asking, do they need to be this precise ? This exotic? Etc. it's a tube with a nozzle on the ass end. I think Elon is onto something

[@Dubbie-gv9ry]

@seancollins9745 When you are working in the vacuum of space, a lot of the intuitive knowledge you have for mechanical engineering turns out to be flat out wrong. NASA and other companies over the decades have build vast volumes of knowledge about engineering reliable systems in space. For example, on earth you might use a simple ball-bearing for a rotating part. In space you can't do that, as the lubricant will off-gas into the vacuum, and your balls and races risk cold welding and seizing up. Secondly, it is very expensive to get your craft into space, so a little extra spent on making all your parts perfectly to print removes one area of possible mission ending failure.

[@nolan122]

@@Dubbie-gv9ryexactly. If your spacecraft has 500,000 parts, and your failure rate is just .001%, then you will have 5 parts fail.

[@kellymoses8566]

@@seancollins9745 If Elon was smart he wouldn't have removed radar from Teslas

[@barrysetzer]

Your electric band saw is pretty awesome Trevor. Now hurry up and put the flats on my endmills for me!

[@seancollins9745]

😂😂😂😂😂

[@trevorgoforth8963]

Why should I? You just keep breaking them! 🤣🤣

[@ipadize]

if he doesnt want to (or can?), then you can mill em yourself. There are tools that can mill carbide :)

[@seancollins9745]

@@ipadize yeah, electric bandsaws

[@ipadize]

@@seancollins9745 wat

[@dermowhittles3803]

Im an edm programmer working on AgieCharmilles Cut30P, Cut20 and Fanuc Robocut in Cpt S.A and all I can you guys are inspirational with what you do and I always learn a trick or 2 watching your videos. That "electirc bandsaw" best ive heard lmao. Great work guys!

[@R_Nedza]

Mitsubishi here.

[@Mithraschosen]

Compliant mechanisms are super cool, seeing yall make these is such a treat!

[@divyajnana]

"Electric bandsaw", i laughed for about a minute. That thing is so cool. Great demonstration/education/process, thank you,,,, Mr. Electric Bandsaw driver.

[@Jessie_Smith]

You are starting to get the hang of this machining thing Trevor. Maybe one day you will even be able to say you are a Machinist!

[@shanemeyer9224]

haha that was savage

[@JonathanDuddy-oq6nv]

That forehead is quite something

[@jonmccormick6805]

Wow Jessie! You even spelled it correctly.

[@markcasper6940]

Lol you guys are such a trolls. Is he an apprentice? What year?

[@trevorgoforth8963]

@@JonathanDuddy-oq6nv Post a selfie, lets see how you look!

[@liamdj6535]

Using that lower flush jet was genius, I have no clue about wire edm but it gives me the same vibe as using a tap wrench to lose. A square head bolt on a lathe tool holder

[@markdavis304]

Solid EDM tips and tricks. Great machine! Amazing part! Nice work Trevor👏

[@frankensteincreations4740]

Insane! Wire edm is mind blowing… 👍🤘👏

[@adamhayes2528]

Super cool and enlightening video! Great job Ben and Trevor!

[@davecox8922]

Love it man - killer info. Love the EDM content.

[@sysop007]

Cutting with wire is insane and clean, no heat. Wow 👏🏻

[@jmowreader9555]

There's only no heat because the part is sitting in fifty gallons of coolant.

[@verakoo6187]

​​@@jmowreader9555 EDM doesnt use coolant, it's deionized water.

[@jmowreader9555]

@@verakoo6187 Water is also a coolant.

[@nicolespittler9530]

That’s an awesome looking part! Great work Trevor!!

[@bboydrummer1]

Thank you for the video. I would like to see more about roughing and finishing on a wire EDM. The finish looks amazing, when I get parts using wire EDM the finish never looks like that.

[@speedking700]

i operate an electric band saw to and im in love with it, i have Mitsubishi FA20s, the only downside of it is that the integrated cam cant program more than 25 parts at the same time and i can't program the parts to cut after everything is done so I'm stuck to separating the program by hand into 2 separate programs

[@shanemeyer9224]

I love Wire EDM for these projects, super accurate

[@Isthisoneavailable]

Shout out to BYU for compliant mechanism game changers.

[@Therealphantomzero]

I like watching CNC videos even though i have no idea how to work one

[@bryanworth8292]

I used to run Brother and Charmilles wire machines. Nothing even close to this part as far as complexity. Burning titanium is cool cuz the arc is bright purple as opposed to a light blue with stainless. I miss this kind of work but makin cereal for "The Big Red K" pays the bills.

[@tykjpelk]

I worked with a flexure stage a while ago. It was the size of a desktop computer and had 150µm travel. Seeing this kind of blows my mind.

[@cheater00]

Hi guys, love to see some compliant mechanisms. Please post more videos about manufacturing compliant mechanisms, I feel like this is the future of mechanical engineering. As well as please post about tensegrity mechanisms. I think between these two you can pull off some really crazy stuff that hasn't been seen before.

[@Kyle.Brouwere]

How perfect something to watch as I'm currently boiling in a makino u6 edm 😂

[@roquri]

Neat way to make roll pins!

[@markcasper6940]

Nuanced machine but easy process with amazing results. Ran Fanuc Wirecutter, as an apprentice. Great to learn principles of precision.

[@jeremymatthies726]

Hey Trevor, your line about tools should have gone "If you need tools, see Barry and Jessie......I mean our website" 😁🤣🤣🤣🤣🤣🤣 Keep up the awesome work guys.

[@trevorgoforth8963]

Hahaha I’m throwing that in the next video 😂

[@jeremymatthies726]

@@trevorgoforth8963 I can take credit for it for you 😁🤣. Always enjoy a good play on words and fun among friends.

[@travisjarrett2355]

I don't care how it is made, that is a cool looking part brother!

[@anthonyfarrell7720]

Ave made a flexture using a mill. He made some cuts, then filled in those cuts with hot glue so that they wouldn't spring during the remaining cuts.

[@zanechristenson3436]

I’m the most stoked about those titanium roll pins you unintentionally made lol

[@johnnyreyna3795]

Nice! Love this content! Hope to see some more !

[@dragnutts]

"Today, there is over a thousand. Elon Musk and Starlink alone have 5,400." That killed my brain.

[@trevorgoforth8963]

Go back and listen closely, I said “over 8000”.

[@dragnutts]

You're right. I did go back and look (like it even mattered lol) I'm sure I was the only one then I have abnormal hearing sometimes @@trevorgoforth8963

[@verakoo6187]

​@@trevorgoforth8963 ah ah he did it, he said the thing!

[@christophervillalpando5865]

GREAT JOB TREVOR!

[@JacobBennett45]

I want to know how that part works. Really cool

[@stuartgray5877]

Lookup the focus mechanisms for the JWST Mirror segments.

[@dienelt5661]

If that looked interesting to you look up compliant mechanisms. It’s fascinating.

[@PuerRidcully]

I would probably use those 1.4 million tilts in the first week of this sitting on my desk.

[@verakoo6187]

Little tip for the slugs to take out having to come back to the machine at all. Since ur part isn't very tall just put a square block under it to raise it up a bit, when the wire cuts and it moves onto the next hole the slug should just drop out. If not add a flush command from the top jet before it moves on.

[@richhuntsd12]

Very informative. I learned a lot

[@ml.2770]

Imagine still measuring in bananas in 2024.

[@shaniegust1225]

Great video!

[@fxlrsaz6363]

It's a very expensive ban-saw and very cool!

[@Felenari]

I'd be down to see a perfect golden mean spiral cut in something weird.

[@bobwissenbach2195]

This looks like a really important part. Have you looked into doing any metallurgical testing on this like the aerospace industry requires for non conventional machining? I bet that would be a tricky part to do some shotpeening on with even fine glass beads. How much fatigue life would you gain if you could do so? I’m just suggesting some things that you could bounce off the design authority for the part.

[@vichenzadoorian7551]

I wonder if 3D printing this part would be a better way to manufacture. I really doubt the tolerances on this thing are as tight as even +/-0.002" as it's a component meant to flex so it has some give.

[@HEYGU1-s2y]

@@vichenzadoorian7551 yes

[@linuxguy1199]

0:30 As a random guy on the internet I gotta say that intro is a joke, I'm not saying the technology isn't a requirement for some projects, but the vast majority of projects tend to avoid using specialty parts like compliant mechanisms (that we're never really around until the 2010s anyhow). Especially back in the day when the GPS satellites were built wire EDM was way more uncommon, since they're extremely large and there was more room for traditional mechanical assemblies, plus the complexity and uncertainty of designing a compliant mechanism in the early 80s meant they were very rarely used. Back then the only real serious use for EDM was for waveguide and oddball RF hardware, and most of that was done via an additive technique known as electroforming, which is a process that starts with a metalized plastic mold inside a chemical bath where a solution of copper ions can be plated onto it, later using solvent to dissolve the plastic out creates the interior features while traditional machining is used to create the exterior features.

[@dakotareid1566]

Compliant mechanisms have been around longer than 14 years lol They’re far lighter than a traditional ways of making something move, everything you can think of has them nowadays, cars, phones, tablets etc

[@rpm4999]

I have been using wire edm for years It has been well used in the toolmaking sector for longer than i can remember and i am 60 this year Extrusion tooling is one industry where it is invaluable but you seldom need to work to tenths when making dies there. 4 axis sim machining is quite common though to get the material flow path correct which can be quite tricky

[@jaredjared8347]

Agree with the gentlemen above. Wire edm is far more common than the original poster understands.

[@linuxguy1199]

​@@dakotareid1566 Sorry, I should clarify, I was talking about the space industry as we tend to avoid compliant mechanisms unless necessary since the failure modes and vibration modes can make them undesirable. Think of all the thin little metal structures in a typical compliant mechanism, now imagine what will happen when one of the many modes of vibration inducted by a rocket starts resonating that thin metal strip, it's really bad for the mechanism and what's mounted to it. So they're pretty much used only as a last resort because of this, plus you still need to add motors, sensors, etc. to actually do any work. To be clear, I'm not talking about MEMS tech or plastic latches, those are everywhere now.

[@linuxguy1199]

@@jaredjared8347 Again, context dude, I'm talking about the space industry, not toolmaking or any of the millions of other uses for wire EDM, we only use it unless we absolutely have too, most satellites don't have a single wire EDM part on them unless absolutely necessary since pretty much everything is designed to be easily mounted with acceptable tolerances and standard sized M1 to M8 hardware. The intro seriously overstates it's use.

[@davidputt4638]

What would be super cool would be a simple exploded view of how the art fits into the mechanism it’s a part of. That would be boom!

[@zeitgeist909]

I really wanna know what that part is for. He was pretty vague - something about star aligning or whatever. Fascinating stuff.

[@NoeticSystem]

Google butterfly flexure pivot, and one of the first things that comes up is a paper on Researchgate by Simon Henein and Peter Spanoudakis with a detailed description of the part. Apparently, they're used for precision instrument orientation on satellites, particularly Fast Steering Mirrors for optical beam guidance. In short, they're used as part of a mechanism that uses a voice coil (kind of like a speaker) and a mirror to precisely deflect laser beams. On a satellite, this might be used for satellite-to-satellite laser communication where you need to be really accurate (i.e. where the precision of the beam angle is measured in microradians, like literally hitting a receiver on a satellite with a laser beam carrying data pulses from another satellite from ridiculous distances).

[@iexcedo6918]

I THOUGHT I WAS THE ONLY ONE TO CALL IT A ELECTRIC BANDSAW. I'm losing it 😂

[@smilintodd]

Would you share the part file of that...I'd like to waterjet it.

[@Islandwaterjet]

Yes if you brought that material into the shop here that is a $50 part on a waterjet.

[@dienelt5661]

@@IslandwaterjetI don’t think you could get the tolerance necessary on a water -jet. Those thin sections need to be extremely consistent side to side a top to bottom. Even with wire RDM I believe we are limited in the height of the part (about a 20:1 ratio in the best case scenario) since some sections are to thin they become hard keep rigid. But maybe waterjet technology improved enough to meet those tolerances, I’d be interested to know.

[@smilintodd]

@@dienelt5661 it would be a question to ask for sure. The surface finish difference would also be a question to look at as far as the fatigue performance. Titanium is notch sensitive, so does even an wire edm finish give susceptibility to that?

[@russellofcnc]

Trevor said, Watch me make an incredibly complex geometry with some water and wire. Outta this world! 🛰️

[@luketorpedo]

The resistance to the vibration and acoustic environment of launch will be a much more important metric than how many cycles it can do in operation I imagine, launch is a horrendous environment. While the actuated mechanism is likely locked in place for launch, parts like this will definitely need to consider resonance. Was there more assessment done in house or is the final design contracted in and the solidworks an in house sanity check of the design (most likely for manufacturability and tool pathing or conversion I'm guessing?)

[@ElectroEngineers]

Allright guys, youve just gave me inspiration to print that thing on my 3dprinter machine. Im curious how that thing will flex 😅

[@christopherleubner6633]

Now that is one high tech shock mount. First thought that this was an easy job for a fiber laser to cut out that is until the use case and tolorance required was shown.😮

[@YoSoyElQuesoGrande]

Cool part, but will you please place a sacrificial shim between that nice ground table and your jack screws? A dollar buys 100 pennies that work extremely well for this.

[@lomobster]

What's the cycle time on this?

Badass! 👍

[@PacoOtis]

Ten times longer than it needed to be!

[@МыАкмурзаевы]

awsome technology

[@pahom2]

Is it really necessary to make external sides of the part sooo precise?

[@KaitouKaiju]

It needs to be in a precise position so yes

[@ricardo-iw9sq]

Nice part but as you said it moves as you cut, as you left a 0.0500 tab then go back to snip the tabs you could have programed a triangle tab and then with gentle tap knock them out and let the skim pass take off the excess, if it's going to move it's going to move due to the springy nature.

[@luckygunner8089]

the X-plugs left over material might make a neat drone frame.

[@gfresh353]

Very cool!

[@u.e.u.e.]

How does titanium flex at almost zero degrees Kelvin? 🤔

[@RainbowGin]

It doesn't skip leg day

[@KaitouKaiju]

It doesn't need to move very far, and there's more than enough clearance to allow for thermal changes

[@u.e.u.e.]

@@KaitouKaiju I mean the material properties steel cracks like glass at -70°C!

[@matsler89]

So I have a question. Does the machine make the holes to then feed the wire through to start the cuts or is this a separate operation that has to be performed on a different machine?

[@trevorgoforth8963]

The start holes are made on a separate machine. Usually a hole popper or a mill.

[@rpm4999]

I used an old agie 100d and that had a startron edm hole drill incorporated into it But i always first opped the holes on the mill

[@supremecommander2398]

@@trevorgoforth8963 You forgot to mention/link the video where someone used that device it to remove a broken tap from an expensive part

[@alf3071]

is the cad model available to 3d print?

[@saintwalker9732]

Curious if this couldn't be achieved easier, in bulk, through investment casting. I've seen some really small and thin parts run through my furnace, so I imagine this is doable?

[@liggerstuxin1]

So does it continually flex until the the metal eventually breaks? Like a spring?

[@KaitouKaiju]

Like a spring except not just in a line. The metal isn't gonna break any time soon because it won't go past the point of plastic deformation

[@mxcollin95]

Impressive!

[@mk3driftmotion]

You guys can make parts for my spaceship anytime.

[@ZFISHTANK]

Did I just hear it's suppose to be a high precision part and then hear they were proud by a .1 which was okay? on the flip side very cool machine

[@ardennielsen3761]

mean while on the farm... building the 8kva mobile power unit is nearing completion, to fix the cracked sucker rod on the water well head... that will eventually get a solar wind module and remote fluid level sensor for filling a 2 acre pond 280 yards away. 600gph when it holds water being fitted once a year. koi sushi costs more then the scrap weight of that part that's out 0.000001'', material items simply accumulate.

[@JamesSpatt]

Why do u need to rough a edm? U can actually get different surface finishes?

[@trevorgoforth8963]

Yes vastly different.

[@RajeshN-f3w]

hi iam working cut 30p- wirecut-could you please add some trick and tips vedieos

[@danyalmedley4926]

Just out of curiosity, how much does an "electric bandsaw" cost? Asking for a friend.

[@johnjacobjinglehimerschmid3555]

LOL. For a person who works and deals with accuracy. We're almost 2million subscribers .... I look and it's only at 815k. That is a awesome friggin part. Need to investigate wire edm machining.

[@ElvargMovies]

can we have the cad please? I want to print it

[@MasterSamus]

I wonder how it avoids cold welding itself in space.

[@Abstract4]

Does anyone know what this part actually actually is? Im interested to learn more about it's application. Saying it goes in space doesn't actually tell me much.

[@DIN_NER]

When is your satellite going up?

[@abludungeonmaster5817]

Use your CNC machine to make a CNC machine. Then do it again, but the first one you printed has to calibrate and polish the second print.

[@MARVINMotorSport]

How do you deal with thinking in thousandths with a machine that works in microns?

[@MarcusMussawar]

you should sell the titanium scrap from the EDC as paper weights

[@roncournoyer7794]

A PC of painters tape gets little parts out quickly.

[@trailfork7815]

by tenth do you mean .1mm or .0001mm tolerance?

[@ratboyiscool]

he is talking in inches .010", you can see the dial he is using is Imperial as well and watch it move the ten thou end to end @6:01

[@trailfork7815]

@@ratboyiscool missed that because the only dial gauges I've ever used was metric

[@ratboyiscool]

@@trailfork7815 makes perfect sense, just figured I'd point it out cheers 🥂

[@lukeharry8648]

Pipe cleaners work well for removing those little slugs.

[@ZURAD]

I will make one of these.

[@JorenMathews]

What is this part for?

[@carnage77]

@Titansofcnc - here is an idea for a small project..... titanium Reed valves for 2 strokes. Any of you guys ride dirt bikes or snow mobiles?

[@jamest.5001]

What if you made something similar to this from say stainless, then added a layer or two of nylon cloth or even kevlar. To the joint areas.. to reinforce them yet maintain the flexibility a composite of stainless , kevlar and a resin that keeps some flexibility and provides a strong bond to the stainless. It may require media blasting or acid etching for a strong mechanical bond. Something that sets up like a polyurethane slightly rubbery. Yet thin enough to soak in the kevlar fibers. Nylon cloth works wellvin very cold temperatures. The resin would need to be similar when setup. The thing about using a composite, thev part would stillbbe one piece. Even if the stainless fatigued to fracture , the addition of the composite should dampenthe fatigue. Prevent the fatigue possibly prevent fracture with a readonable range of motion. It should push the flex out to the center of the thin ares away from the transition area from thick to thin. The area most likely to fracture is close to the thick portion. It should act similar to a strain relief on a power cord.

[@leonschumann2361]

would have thought something like would be cut from front to back, pocket by pocket. so you have maximal material new the fixture

[@9greatdanes981]

What metal do they use, because the thermosphere is over 4,000 degrees? Titanium would melt.

[@ironfistvail]

you guy should build a small engine with a piston cut with EDM see if you can run it with no rings like a 2 stroke

[@jamesg8246]

As a Toolmaker before watching the video, see video title that says a part is impossible to machine, see part that's not even difficult to machine with a wire EDM machine, and wonders what impossible means to people.. Think possible.

[@gkarapeev]

Why does this part have to have such a compex shape? Based on absolutely no calculations at all, to me it looks like the part will have areas of very high stress - the edges of the flexible sections. And some areas of low stress, which is what we want, I assume? Lower stress means more durability. The only reason I can think of is if we want some very specific curve of resistance across the range of motion?

[@KaitouKaiju]

To fit within a larger structure for as little weight as possible overall since it will eventually be part of a satellite

[@gkarapeev]

@@KaitouKaiju but this doesn't look like 'as little area as possible'. Why isn't it a simple bendy sheet of titanium? Just a simple rectangular bendy bit with mounting holes at the edges.

[@miscellaneousanus2831]

It’s all fun and games until you have to fix that electric bandsaw. Such a headache but makes some beautiful parts.

[@jhudson_tiedye]

i am curious why is this better than a hinge

[@jeffwombold9167]

It is probably because hinges in a vacuum can spontaneously weld the two metallic parts together. They actually had hatches stuck on a spacecraft because it had hinges. Metals (or most other materials) don't have a protective molecular atmospheric layer between them in space, and when they touch, they meld together. That's why so many materials used in spacecraft aren't what we see here on earth. They also sublime (evaporate from solid). I.e. ball bearings are ceramic. Steel would gradually evaporate into nothing.

[@dienelt5661]

Basically infinite lifespan (no wear and tear of the actual mechanism) if use within specs, really robust, and the tolerances on the movement are almost perfect. But since it’s designed to be in space it also has the advantage of being more optimal for weight when considering the saving this allows for the whole assembly and as someone else said their might be a problem with cold welding.

[@thomasmedlin2881]

Doesn't look like the part has been surface ground?

[@edlomonaco]

A one piece part that can move is called a " compliant structure".

[@daynosdr]

I hope that thing is an example part. looks way too inefficient for flight

[@deathblowhere]

same as their "fuel manifold" without internal cavity of the valute..hah

[@seanmcclure2006]

I’ve never used an edm, but that part took 3hrs? From what I’m seeing half of that part could be machined.

[@trevorgoforth8963]

Which parts? You’ll never achieve the positional accuracy required if you machined the holes or really anything on another machine. Cutting it from billet on the wire essentially ensures the positional accuracy is as good as the machine is capable of, which is very very good.

[@seanmcclure2006]

Yeah I was thinking the holes and most of the border. What if you bolted down a jig and used the edm to cut the reference holes and turned some reference pins to fit the machined holes? Or something like that using the edm to cut the references

[@CAMER_21]

niobium heard name??? ever do milling on niobium??

[@rpm4999]

It mills a bit like nickel

[@CAMER_21]

@@rpm4999 i did make parts but cutting parameters is so slow😉

[@rpm4999]

@@CAMER_21 i had to drill and tap M1.6 holes in niobium part

[@CAMER_21]

@@rpm4999 i had to run 0.75mm endmill for milling 0.8mm slot 6mm deep parellel slot both way wall of 0.8mm

[@rpm4999]

@@CAMER_21 I would have refused and told them to spark erode it 😀

[@arnolaurie9928]

Look up Simon Henein if you want details on this compliant mechanism