Drambeenie Risers MEGATHREAD.

[johan]

Originally Posted by Drambeenie

It really is the quality of materials that make this pricey, because I'm using really great materials. As my first product, I wanted to make sure this would last a long time, have perfect fitment with no issues, and be able to handle all that might be thrown at a rear spoiler.

Side note: If anyone knows about wind tunnel testing software - PM me please! I would love to prove the functionality of the wing

Verus (Velox) uses Ansys. They will do simulations for you for a fee, but it's not cheap.

[Drambeenie]

If you've been following the threads here and here one thing I've been talking about lately has been the quality of the parts.

I've spoken to many people who had no idea about the type of 3D printing that's been used for creating this part, so I thought it would be great to talk a little bit more about that.

3D Printing: Many different flavors, many different results.




When people typically think of 3D printing, they imagine FDM - Fuse deposition modeling. Basically a glue gun of plastic builds really tiny layers (typically 200µ or 100µ - Layer height). This is the "cheapest" but most consumer friendly 3D printing available. Unfortunately the finish layer lines are very obvious and difficult to finish, which is why it didn't suit my needs for this part - But it was great for prototypes and test fitment! (As seen below)





Then there's SLS and SLA 3D printing, which is what the Drambeenie risers are made of. The risers are made of two pieces. If the cover was the only part of this project, it would be much cheaper - But the part is much more complicated than at first blush. The inner core is really where the strength holds up. But the cover with the core make it unbreakable.

The covers are SLA (Stereolithography) printed. Imagine a giant puddle of goo, and a projector that flashes into the goo. The projector and the goo interact and where the light is shined, the goo hardens. Then the really thin hardened layer is lifted and another image is projected and the goo hardens. Seriously some sci-fi shit. See below.



This material is extremely strong, similar to ABS and the finish is nearly perfect. SLA printing will for sure get you the highest quality print that requires minimal finishing before being painted. ABS has a tensile strength of 6,600 PSI, the same as the Somos material we're using. If ABS is the go-to material for automotive performance, it's what I wanted to match with my part. Here are some pics right out of the printer with no finishing yet done.

See how smooth?




SLS (Selective Laser Sintering) is what makes the inner core and is a pretty fascinating technology. I only learned about it as I set on this adventure to make this part. Basically what happens is a sheet of powder is spread on a plate. Then a laser sinters the powder. Another sheet of powder is spread across, and then more laser sintering. After several hours, it builds up and then you can retrieve your part from this powder - as if you're dusting off Dinosaur bones.




The inner core is Glass Nylon. So similar to how fiberglass is a fiberglass reinforced plastic, this material is glass reinforce nylon. Because this piece is made with lasers, it requires extremely high temperatures which is a lot of electricity over the hours and hours it's required to print the part. Plus the powder is also pretty pricey.

The Glass Nylon has a tensile strength of 5,200PSI and a Flexural strength of 8,800PSI. Of course the design plays a big part in the piece's strength so we tried multiple prototypes and landed on a design that has 0 flex, vibration or bending when driving - Even on extremely cobblestone NYC streets.

Here you can see the inner workings of the cover.


Hopefully that gives you some insight, and some behind the scenes into the development of the part!

I'm currently running a two week pre-order, which you can find more info here!


Let me know if you have any question's about this process. I'm happy to chat!

[Drambeenie]

Originally Posted by Bonburner

I hope you get a hold of someone that can help you with a wind tunnel .. that way you can make sure the angle that the risers set the spoilers don't mess things up ~

granted its kind of hard .. just angle the rear side higher than the front and that should do it lol

Working on it! Higher and further back would have no negative impact as it brings the spoiler into cleaner air and there is now a larger area for air to travel under the spoiler.

I’m going to be making a profile of the wing and see if we can test the airflow.

[Aluma007]

you know, it just dawned on me...maybe subaru kept it low for automatic carwash purposes? :P

[Drambeenie]

Originally Posted by Aluma007

you know, it just dawned on me...maybe subaru kept it low for automatic carwash purposes? :P

Haha don't worry, I tested it through the automatic car wash too! The guy was actually able to clean under the spoiler when it came to wipe down. He was funny he goes "Uhh...Wait, didn't u have another spoiler?"

Also

[mjanmohammad]

Just ordered mine, can't wait! I'm gonna be doing some rudimentary testing on track too. I'm going out this weekend with the OEM wing height and then again after the risers. Hopefully theres enough time for Vorshlag to figure out the sensors we need.

[Tcoat]

Very cool write up on the methods there Dram! I had no idea how the quality work was done.
Here's hoping you do well and can start in on some new projects.

[jmark]

I suspect Subaru kept it low due to restricting the view out the back window. Pics look good.

[tacos]

placed my order earlier today, cant wait! this is gonna look so much better, and im looking forward to not having to clean out the leaves that get caught in between the trunk and spoiler anymore lol

[mjanmohammad]

Originally Posted by Grady

Possibly 3 for Dalas!

Make it 4!

[Tcoat]

Originally Posted by jmark

I suspect Subaru kept it low due to restricting the view out the back window. Pics look good.

If they made it too high people would scream rice. If they make it too low people say it is useless. This is why it is a great time to be into modding since guys like Dram can use the tech available to make parts that satisfy the desires of a small group but still keep the price very reasonable. The big names would never make this product and if they did it would cost much more.

[tony-brz]

Ordered. I absolutely love that you took this project on and just made it happen in a seemingly amazing fashion. The 3D printing future is no joke !

[Drambeenie]

Very much appreciate the orders fellas! You’re going to love em

[tacos]

Originally Posted by mjanmohammad

Make it 4!

At this rate, if you have a 2017 in Dallas and don't have the risers you're gonna look out of place