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.

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

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

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.

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 =)

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.

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.

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

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.

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.

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

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.

"somehow lost the blade guard" "lost"

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

@Stuff Made Here Happy one year since your first KZfaq 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 KZfaq career closely and permanently. Thanks for your hard work and excellent content. You're appreciated to infinity and beyond. Cheers

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

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

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.

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

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.

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

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

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.

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

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

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

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.

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!.

Great project and really well presented!

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

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!

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

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

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

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

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

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

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

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

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.

"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 🤣

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

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

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

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.

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

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 !

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

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

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

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

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

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?

There are videos here on KZfaq 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

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....

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..

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

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

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

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

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!

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

This video has shown up in my KZfaq 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 KZfaq 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.

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

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

15:45 nice vise!

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.

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

3d magic Mike has done many 3d printed dies

Has tormak, does not have color printer.

Brilliant, innovative AND persistent = BRAVO!

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

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?

"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

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.

Really enjoyed watching. Keep making these great videos! To fix the camming issue you experienced you could try replacing the hole in one of the white bushings with a slot (if you haven't already done so, hard to see). With two holes the system is over-constrained and more inclined to jam.

How many people are waching this cas it is his first video

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

Nice job, man. There's nothing at all wrong with printing hobby models, but it's great to find a youtuber using 3D printing for actual functional parts for once. I have a resin printer (highly accurate but the resins are typically even more brittle) but use it to print either a form which I can make a silicon mould around and then cast one out of a high-strength, two-part resin, or if geometry allows, print the mould directly, add a release agent and just pour resin straight in . Asides from the obvious benefit of having stronger forms, you can also use much less print resin (or filament) as most of the structure is infill because it doesn't need to be strong. Can also add glass fibre or carbon fibre to the two-part resin to further increase strength. Obviously this creates one more step, but it's a good middle ground between expensive, machined metal forms and brittle, instant 3D printed parts.

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

Next step, an ak bending jig lol

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

Just... WOW!!! Your channel went VIRAL!!! 115K Subs in 2,5 MONTHS!!! Keep it up, and keep building such cool stuff! Also a collaboration with This Old Tony could turn out great!!!

Your vise setup, you need to show that, looks interesting. I bend stuff in my vise often but much more of a hack. I like the video, good job good lesson. Best of luck to you. Cheers!

Milling really is just 3D unprinting. :D

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. kzfaq.info/get/bejne/rt1lrKh-2Krcgmw.html

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

Wow. Who knew you could press metal with plastic dies (well, at least once 😉). That's impressive. I would have tossed the idea straight out, but you proved it can be done. Very impressed!

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

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

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

First and more importantly, this was a really neat video. Second, I just saw a video on PSU material if you have the enclosure, heated bed (160 degrees, so ac powered bed), and all metal hot end to do it. Very strong stuff. That all being said, I laughed when you said A Holes. My inner 12 year old is alive and well.

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

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...

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

Awesome ! Very interesting! Thanks for sharing

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

This is really cool, the spring design was super well done. Normally I would expect the blade guard on a sawzall to have a little bit of pivot along the axis of the rivets so it can stay flat to your work piece.

I love your what you do man. Super rad

I really love your videos! thanks!