Been playing with many different approaches to a 3d printed hockey puck. I gave up on the leather texture and instead have gone for a nod to the original but one that instead looks good and prints easily. That means two pieces and a larger emblem.

I have it as two pieces now so the detail of the emblem is good on a filament printer (you need to print it at an angle with supports but the puck sides are printed flat on the board for best results with no supports needed. I have not uploaded these to my collection on thingiverse yet. I will provide instructions on printing when I do. If you have a resin printer the single piece form with the smaller emblem will work fine.

https://www.thingiverse.com/thing:6238862

These were printed at low resolution. I will print a high resolution form, paint and assemble when I get a chance.
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That's very nice!

Well, I think I have gotten it to where I am happy.
Raw off the printer:
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and here it is painted.
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This is the '6.3-biggerhole' stl on my thingiverse.com page (that refers to the indent on the inside for the rubber bumper).

https://www.thingiverse.com/thing:6238862

This is a good compromise between ease of print and 'faithfulness' to the original design. I figured a single print design would be better for everyone and this does just that. This was printed at .12 with a .4 nozzle on a longer lk5 pro. It looks pretty good on my anycubic kobra 2 neo as well, same settings.

I have two models set, one for just screwing straight into, and another setup for threaded brass inserts (the better way).

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Popped it on the garage bound car today. Could be just a hair larger in circumference but otherwise worked great. I have just bumped up the diameter to 105 from 100. Will have to print another one I guess...
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That’s cool dude

I love the work but just an idea. I think if the crest was the same size as the factory used, I think the proportions, IMHO I think it would look better. Also, color filling and sanding may look very cool.

Shown is a real factory puck. Used it was like $450. On Ebay 15 years ago. I also had to try a few different leather puck faces till we got one that was good enough.

Best Bob B


Best Bob B
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Pretty amazing , what can be done , modern times...
Here is a pic of an OG Puck...
The dia. at the top of stripes is 98.50mm and tapers to 108.550 at the base of stripes, Stripes are 1.0mm tall at the base of puck ...

The second pic is of the First version and the Last version...
Note the insert was only a press fit,The Later had tabs to bend over to
retian leather ...

Well Its Snowing ...So,, Early Versus Late...Early on right,,
Here are the dimensions and visual between the two..
OD at top of stripes, 99.00mm, and the Bottom 110.00mm, Stripes are 1.50mm tall at the base of puck ...

Pictures of OG puck used for my built. Just for reference

Best Bob B

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Very Nice Bob B.
As found,, Yrs ago...

Awesome! Thanks for those measurements. I knew I was getting closer but now I can hit it dead on. Sadly the crest has to stay unusually large for the average printer to handle the detail and print on one go. Eventually I might create a normal sized crest version again but I don't want people trying to print it and getting terrible results. My mission here is a good looking nod to the original that anyone can print. If someone could give me a measurement of the crest top to bottom side to side, that would be great too.

@emerygt350

That emblem looks great.
What layer thickness are you using?
Did you do any post processing like sanding or trimming?

These were done at .12 with a .4 nozzle. Ultimaker 5.9 and a longer lkr5 pro.
No post processing at all besides removing the internal supports. I tried an acetone wash on one, but it didn't do anything I liked.

Is that 110 the diameter of the puck or the diameter of the 'bumps' at the base?

I think I like the look of the early version more.

Here we go again...
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yes, dia. of bumps... I can Get you any measurement you need,, later today..

Sweet, so then the cylinder diameter at the base must be 109.5?

The other measure I would like is the height from the top of the 'bumps' to the top of the bevel.
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Well, here is a small logo version of the new design with the flared base.

Gonna print it and see how it goes...

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@emerygt350

On to the great work that you are doing on the horn pucks. These pictures show the leather part as Dale contoured it for my 6 build. My factory old puck was less than flat same as @sixnotfour showed us. You can see how the leather has shrunk down as the padding material under the leather aged. If you could put the slight dome contour on your as well as the leather texture on it would be a fantastic item for people. I hope that you will come up with a way to monetize all your hard work!

By the way I do not care what the Chalon hatters saw, I love the look of the Porsche 914 Chalon body, have from the late 1970. I had thought of doing one and putting the aluminum front and rear bumpers and real rubber accordion pieces from real 911s or 924 and Valances so it would not get damaged from scrapes in the real world. Just my thinking in the 80s

Best Bob B

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Thanks for the images. I have created several leather textures but sadly 3d printing doesn't have the resolution to execute them. You can almost do it if you print it at an angle but that creates other issues.

The leather insert costs around 75 dollars I believe, perhaps I will make a version you could just insert that into.

I do this for the challenge. It's like a crossword puzzle for me but I have something useful when I am done, and some improved skills with CAD.

Long live the Chalon!

Ok, Snow melting,
The upper dia. is 99.00mm
The step down at that dia. is 6.50mm
The dia. just below above dia. is 102.50mm

Great. I was very close. I guessed 7mm

old shrunk crest is 30mm x 37mm

The puck to the top of chrome is 2.5mm, and is 89.50 in dia.

Width of chrome ring is 2.75mm

Ok, quick update of the files today. I have now changed all of the measures to match what you guys have so thankfully provided. Looking pretty good. I am testing out the brass insert holes today (made them larger) and will start printing what I hope will be the final product. I kicked the little buttresses out to the 1.5 mm at the base. That was hard to do with the polar array in Blender. It really is like juggling twelve plates at the same time.

Here is the small logo version:
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And the large logo:
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And here is the print of yesterdays design before the last little changes today. I printed the small logo 'suspended' which allowed me to get a little better resolution on the logo. I rinsed it in acetone a couple times and then painted it. Didn't turn out too bad. You can see the brass inserts underneath.

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I am going to start printing the newest design and tomorrow I should have it all finished up!

And these files are all updated on thingiverse if you want to give it a go.

https://www.thingiverse.com/thing:6238862

And here it is mounted in the car. Just about perfect! Can't wait for the new one to finish printing with the slightly more accurate dimensions all around.



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Very Nice !!!

Here's a pic of my vintage version..

Thanks! Next step is getting the chrome ring right...

Very nice! I had a friend that did vinyl seat and dash repair several years ago. He would fill and apply some kind vinyl adhesibe and use multiple different vinyl patterns to press in the graining then mask and paint the dash or seat bolster to match. He would travel around to dealerships and do this. My point is, maybe the graining could be added in a similar manner.

I think something like that would work here. I am thinking about fillers...

Not that you need to replicate the exact look. It's cool that you have have the skills to do this.

Chrome ring added.

Now to see if I can print it in ABS. PLA can't take the uv and the heat inside a car. ABS is hard to work with though.

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Very nice, very nice!

Ever so much closer. Just have to fine tune the clearances on the chrome ring.
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@sixnotfour Can you send me the total height of the puck from base to the top of the chrome?

About 31.25mm

Also the leather had a pressed dia. that went under chrome , That made it start about 1.0 to 1.5mm higher than chrome.. not sure about the curved
height of leather originally.

The pic shows what was originally under the ring...2 different pucks...

Excellent, thank you.
I haven't decided about how much I want the 'dome' to exceed the top of the chrome ring. I can't really make the squashed sphere (yet) that the leather creates in real life so currently at its center the sphere I am using is there at about 1-1.5 above the chrome. I will have to see if I can create that kind of a buldge.

Here is this morning's print.

unpainted. Used some gold-colored filament for some flair.
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Here is the final print, painted and ready to go.
Small logo is abs and the big is a pla test. I am going to expose it to car cabin heat and see what happens.

All the stls are up on thingiverse https://www.thingiverse.com/thing:6238862


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When I put it on the car tomorrow I will post a picture.

Fantastic...

Might be a good option if you are worried about people stealing the real one. That would be one disappointed thief.

And here it is installed.

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I must say... it's very handsome,,, Nice job!

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I would be tempted to sand it down to remove the resolution marks on the face of the puck.

Cool idea!
If you know someone with a resin printer you should be able to really clean up the resolution.

Zach

Yeah, we have one but it is down. I have been working on a spare print looking at sanding and putty. I am not so thrilled with the results. It just doesn't make it look any more 'real'.

Resin won't let me add the brass inserts and it gets quite brittle so even screws get a little dodgey.