Custom Waterjet Cut Parts

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Big Blue Saw   10 W

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Custom Waterjet Cut Parts

Post by Big Blue Saw » Mar 27 2013 8:02pm

Big Blue Saw has been around a while making custom parts for both professional and hobbyist EV builders. One of our recent customers suggested that I visit ES to get in touch with the best of you.

Some of you may be familiar with our work for MattyCiii. He just needed a simple bracket. A lot of our work is brackets, adapter plates, and the like.

A more elaborate example is what we did for Shane Colton's tinykart. We waterjet cut most of the major pieces of the frame for his 55 pound, 4.1kW electric cart.

Use this link to find out more about how you can upload a design, get an instant quote, and order through our website.

Also, through April 27, Endless Sphere users can take $10 off their first order by using coupon code EVPOWER2013.

Let me know if you need any detailed information about how we can help you.

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spinningmagnets   100 GW

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Re: Custom Waterjet Cut Parts

Post by spinningmagnets » Mar 27 2013 8:14pm

Can you water-jet steel? can you order 2.5mm (0.098") steel plate? What is the thickest aluminum plate that works well with your cutting process.

edit: I just took a quick look at your website...I'm impressed by your free CAD program and the fact that you have a tutorial to help potential customers use it. That's a big stumbling block to a lot of potential customers that many water-jet/laser-cut/CNC places don't seem to want to be bothered with.

edit: using this post as my personal index. For my project, BBS has

Stainless T-304 in 0.090" = 2.3mm,
Cold Rolled Steel A366/1008 in 0.090" and 0.105" (2.7mm),
(less expensive) Hot Rolled Steel A569/ASTM A1011 in 0.105"

edit: just watched the 10-min tutorial, I highly recommend it to everyone here. After drawing your part, easy material selection and checkout at 8:48, huge per-piece price break for 5 pieces (instead of just one), and roughly 25% more at 10 pieces (compared to 5-piece price).
Currently, the only vector format Big Blue Saw supports is 2 dimensional AutoCad R12 DXF format files. GIF and PNG
ordered first batch of parts at lunch on 4/17th/13
Last edited by spinningmagnets on Apr 17 2013 1:58pm, edited 4 times in total.

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liveforphysics   100 GW

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Re: Custom Waterjet Cut Parts

Post by liveforphysics » Mar 27 2013 9:25pm

Very cool service to offer! Water jet cutting is amazing how well it works even on very hard materials. I had some titanium that I couldn't cut with carbide (likely just because I suck at machining), and the waterjet cut it like it was butter.
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Re: Custom Waterjet Cut Parts

Post by neptronix » Mar 27 2013 10:27pm

Welcome to the forum! we could always use services like this.
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Re: Custom Waterjet Cut Parts

Post by Farfle » Mar 27 2013 11:16pm

Very good to hear from you guys. I may be running my genesis dropouts and brake mounts thru you guys. As I'm not happy with our local cad shop
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neptronix   100 GW

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Re: Custom Waterjet Cut Parts

Post by neptronix » Mar 27 2013 11:36pm

The prices look rather good when made in quantity.
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My first major build: 1.6kW 8T MAC motor on a Trek 4500.
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Re: Custom Waterjet Cut Parts

Post by Lionstrike » Mar 28 2013 2:20am

I've heard nothing but good things about Big Blue Saw. Seems like an awesome service.

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spinningmagnets   100 GW

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Re: Custom Waterjet Cut Parts

Post by spinningmagnets » Mar 28 2013 7:57am

I was looking at the customer projects page. The leaning tadpole is awesome. Big Blue Saw, I recommend you edit the first post and change the title to include laser-cut, and laser-etching.

http://zeept.wordpress.com/
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Re: Custom Waterjet Cut Parts

Post by Big Blue Saw » Mar 28 2013 9:06am

Our FAQ on materials lists all the materials you can order from the website. We can get other stuff, too, just ask.

Aluminum plate is practical up to about 1 inch thick or so. We can do thicker, but you probably don't want to pay for it.
spinningmagnets wrote:Can you water-jet steel? can you order 2.5mm steel plate? What is the thickest aluminum plate that works well with your cutting process.

edit: I just took a quick look at your website...I'm impressed by your free CAD program and the fact that you have a tutorial to help potential customers use it. That's a big stumbling block to a lot of potential customers that many water-jet/laser-cut/CNC places don't seem to want to be bothered with.

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Re: Custom Waterjet Cut Parts

Post by Big Blue Saw » Mar 28 2013 9:11am

Our laser is only 100 watts, so it's mostly for plastic, wood, etc. This can be useful for spacers, gaskets, electronics enclosures, signs, etc.

I figured that most of the interest here would be around aluminum and steel parts, which we cut on the waterjet.
spinningmagnets wrote:I was looking at the customer projects page. The leaning tadpole is awesome. Big Blue Saw, I recommend you edit the first post and change the title to include laser-cut, and laser-etching.

http://zeept.wordpress.com/

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Re: Custom Waterjet Cut Parts

Post by Drunkskunk » Apr 25 2013 8:59pm

This comes at a good time. I've got a brake rotor design I want to create. Now I just need to learn the CAD program
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spinningmagnets   100 GW

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Re: Custom Waterjet Cut Parts

Post by spinningmagnets » May 01 2013 7:43am

Parts arrived 14 days after I placed order when using the cheapest shipping option, YMMV. The parts will need to be de-burred on one side, but that is to be expected. LightningRods is recommending finding a local shop to perform an electroplate zinc finish, and those type of shops often have the equipment to perform a cheap tumble-deburr...
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Re: Custom Waterjet Cut Parts

Post by migueralliart » May 01 2013 12:19pm

Ordered the 25th of April ...

Got them delivered yesterday. I did pay 2nd day shipping thou. Excellent service will use them again for my projects and designed parts.

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ambroseliao   100 kW

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Re: Custom Waterjet Cut Parts

Post by ambroseliao » May 01 2013 1:13pm

May I ask what these are for? Just curious...
spinningmagnets wrote:Parts arrived 14 days after I placed order when using the cheapest shipping option, YMMV. The parts will need to be de-burred on one side, but that is to be expected. LightningRods is recommending finding a local shop to perform an electroplate zinc finish, and those type of shops often have the equipment to perform a cheap tumble-deburr...
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Re: Custom Waterjet Cut Parts

Post by MattyCiii » May 01 2013 3:05pm

Big Blue Saw also made my left rear custom dropout/motor mount combination on my A-Line. I'm very happy with their work and will definitely use their services again next time I need a similar part

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spinningmagnets   100 GW

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Re: Custom Waterjet Cut Parts

Post by spinningmagnets » May 01 2013 6:40pm

May I ask what these are for? Just curious...
The plates (sheets?) are a mount for the crossbreak conversion BB-drive. They will have optional outer plates to hold MAC, Bafang-BPM, or possibly a Turnigy 80-100 + jackshaft.

http://endless-sphere.com/forums/viewto ... 50#p719603
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Re: Custom Waterjet Cut Parts

Post by ambroseliao » May 02 2013 1:24am

Thanks!
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spinningmagnets   100 GW

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Re: Custom Waterjet Cut Parts

Post by spinningmagnets » May 02 2013 8:36am

The smallest drawing grid-square on the BBS canvas is 1/32-inch (which is also 0.8mm), and you can also draw with 1/16, 1/8, and 1/4 inch grid-squares Bouncing back and forth as needed at any time). I found it helpful to make a chart to convert arbitrary measurements into 32nds to speed the conversion of a physical part into a BBS drawing. By that I mean that my design process is to cut out manila office folder material into shapes (with scissors) that can be held up to a bicycle frame and that method allows me to quickly and easily find the shape that performs the job while not conflicting with surrounding parts.

Once the cardboard is cut to shape, I measure the shapes with calipers and find the centers of the circular portions (BBS and also machinists perform their prep lay-out by precisely locating the centers of the round shapes). I then use this chart while drawing on the BBS CAD to determine where to position the shapes within a 32nd of an inch.

The canvas is 32-inches by 32-inches, and I chose the 10-inches down and 10-inches over "point" as the centerpoint to make referencing easier during the drawing process.

A metric grid would have been a nice option, but they don't have that yet....


32nds = thousandths / fractions
_______of an inch__/___of an inch
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

1/32 = __0.031
2/32 = __0.063___1/16
3/32 = __0.094
4/32 = __0.125___1/8
5/32 = __0.156
6/32 = __0.187___3/16
7/32 = __0.219
8/32 = __0.250___¼

Xxxxxxxxxxxxxxxxxx

9 _= __0.281
10 = __0.313___5/16
11 = __0.344
12 = __0.375___3/8
13 = __0.406
14 = __0.437___7/16
15 = __0.469
16 = __0.500___½

xxxxxxxxxxxxxxxxxxxxxxx

17 = __0.531
18 = __0.563___9/16
19 = __0.594
20 = __0.625___5/8
21 = __0.656
22 = __0.687___11/16
23 = __0.719
24 = __0.750___¾

Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx

25 = __0.781
26 = __0.813___13/16
27 = __0.844
28 = __0.875___7/8
29 = __0.906
30 = __0.937___15/16
31 = __0.969
32 = __1.000___1-inch

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spinningmagnets   100 GW

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Re: Custom Waterjet Cut Parts

Post by spinningmagnets » Feb 01 2014 11:08am

Big Blue Saw has a page that shows how to convert a Google Sketchup drawing from their .SVG file type option, into an industry standard .DXF file. It involves downloading a plug-in upgrade to Sketchup. I haven't done this yet, but I may try it soon...

I have found that BBS's in-house proprietary 2D drawing program to be very easy to learn for the type of basic shapes that I might need, however, this ability to convert a Google Sketchup SVG file-type into a .DXF file will help anyone of us that may also need laser-cutting or 3D-printing from another vendor.

http://www.bigbluesaw.com/saw/big-blue- ... tchup.html

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spinningmagnets   100 GW

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Re: Custom Waterjet Cut Parts

Post by spinningmagnets » Feb 07 2014 8:04pm

I just wrote an article that includes a section on water-jet and laser-cutting. It would be wonderful if any of you guys could give it a quick look to see if I made any mistakes, thanks in advance!...

http://www.electricbike.com/cadcam-the- ... st-friend/

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zener   1 kW

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Re: Custom Waterjet Cut Parts

Post by zener » Feb 08 2014 12:45pm

Thanks nice work very informative.
I want to ad that LibreCAD is also a free and very good tool to draw 2D parts it saves into .DXF file without plugins.

After you watched all the videos here:
http://www.youtube.com/user/TheReimber/ ... y=librecad
You will have all you need to draw eg. torquearms ect.

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Re: Custom Waterjet Cut Parts

Post by Big Blue Saw » Jul 02 2014 8:10pm

Hey all,

Just a quick note: we're running a sale on waterjet cut 1/4 inch thick aluminum next week. This is stout enough to make a great baseplate, motor mount, or bearing block, but could even be used for a control panel or emblem. If you've been holding off on ordering a custom part because of the cost of a small order, this is a great chance to try us out.

Some more details on the sale and how you can join in:
http://www.bigbluesaw.com/big-blue-saw- ... y-7-9.html

Let me know if you need more info.

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Re: Custom Waterjet Cut Parts

Post by Big Blue Saw » Jul 07 2014 2:17pm

Reminder: the sale is on now! Try some of the example parts on this page to see how it works:

https://www.bigbluesaw.com/big-blue-saw ... sampleFile

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Re: Custom Waterjet Cut Parts

Post by Big Blue Saw » Sep 10 2014 4:21pm

I just wanted to note that we have added 7 new thicknesses of stainless steel to the online quoting system:
http://www.bigbluesaw.com/big-blue-saw- ... lable.html

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Re: Custom Waterjet Cut Parts

Post by agniusm » Sep 13 2014 11:26am

Although I cant order from you because of logistics, I would like to ask couple questions if you dont mind? What are tolerances cutting parts with waterjet? Is 0.3mm copper suilable for this method when tolerances has to be within 0.3mm?
Could you give a reference price on these:

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[The extension dwg has been deactivated and can no longer be displayed.]

Thanks

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