On April 29th, I created a post titled “2nd boring, but necessary 3D Print project”. A piece of a lock inside a sliding door in my house had broke. Not being able to find a replacement anywhere, I wondered if I could scan it, touch the scan up, and 3D print it at DS.

In the end, the print out was a success. But the process to get the 3D printout was different than I originally thought it would be. This is my story…

I met with Valentin Poulain, who is an intern is DS’s 3DEXPERIENCE Lab in Vélizy. He was to help me make the piece. Valentin is enthusiastic and is an expert in 3D printout materials and processes. He gave me a quick tour of the Lab. Valentin pointed to what looked like thin plastic strings rolled around scrolls, and explained that these were actually the materials spools used in DS for 3D printing. I also saw the printers themselves, as well as other tools in the FabLab. I learned that Valentin and his team works with start-up companies who have project needs where the DS Lab can be of benefit to them.

Valentin glued together the two broken pieces forming the lock piece that I wanted 3D printed. Then, he sprayed it with white chalk which, I learned, allows the piece to be seen more clearly by the 3D scanner. Afterwards, he put the piece on a plate that spun in a circle, set up the cameras to 3D scan it, and hooked up his computer. However, probably due to the small size of the piece (~2 cm/1 inch in diameter) the scan wasn’t clear. No worries, Valentin said, we can create it in CATIA.

Valentin took out a caliper, made many measurements of the piece, and entered them one at a time in CATIA, Part Design app. In a few minutes, I was amazed to see the piece in CATIA.

Valentin measuring the piece and entering the measurements into CATIA

We decided to make a quick print out of the piece that was in CATIA, just to make sure that everything was fine with it. We printed it out in plastic.

3D printed piece

I then brought the piece home to try it out. We learned that for some unknown reason, the diameter of the square hole was slightly too small (smaller than the measurements in CATIA), and the square axel (connected to the door handle) would not fit through it. Otherwise, the piece worked perfectly.

The 3D printed draft piece in the door lock

I reported to Valentin the results of testing the draft piece at home. Valentin then suggested making the piece in nylon, a strong material, and he said that he could make the hole slightly larger.

Support for the piece in white, and the piece itself in black starting to be made

The final outcome, the piece on top of the support (which I learned was also made, and then recycled)

I brought the final piece home. It is perfect! The square hole is exactly the correct size, as well as the rest of it. My door once again locks! :-)

Many thanks to Valentin and to the 3D Lab!