Big  Blue Saw

Customer Success Stories

 
Chris Einerson of Postmark USA wrote in to tell us about how they use waterjet cut parts from Big Blue Saw to save time and money and deliver a finished custom project in less than 2 weeks.
 
We have developed an industrial turnkey solution for high speed inkjet printers used in the mailing industry. Our inkjet printer can print at speeds up to 100,000 pieces of mail per hour and are usually used for printing the address and barcode for direct mail applications. Other applications outside of mailing for our industrial print heads could be printing barcodes, lot numbers, or serialization. 
 
Postmark has developed a modular mounting system that allows our customers to order custom mounting solutions which can be tailored to any piece of equipment. The mounting system we developed uses a handful of waterjet parts to make an industrial linear slide with height adjustment that runs across a piece of aluminum profile. This slide allows for easy position adjustment of the single pass print head. The 1" thick waterjet brackets bolt down to a conveyor system and allow for the entire bridge mechanism to be hinged up for cleaning the bottom of the cartridges that are installed in the printhead.
 
The main reason for choosing waterjet on this project was the timeframe and cost. After looking online for quick turnaround vendors I found your website. After doing some cost analysis we determined that waterjet would be very fast and the online quoting tool was very helpful.
 
We designed the product around using water jet for the majority of the parts and we were able to make small adjustments in the design and get a quote on the fly. This helped us quickly design the system and we were able to have a system ready to ship to our customer within 2 weeks.
 

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From the reckless abandon blog comes Brian Stephens' story of an how he used Big Blue Saw to help improve his video arcade cabinet.

The mounting plates on his new Ultimarc Mag-Stik joysticks didn't match the holes on his cabinet. So back in August Brian took advantage of Free Part Day to create a new set of custom mounting plates. The plates are made from 0.125 inch 6061 aluminum. Check out reckless abandon for more details.

Rick Johnston was working on his  Factory Five Racing MK4 AC Cobra replica (shown above) and wanted an upgraded braking package. His solution: custom brackets waterjet cut from stainless steel by Big Blue Saw.

Once he's tested out the parts and worked through any bugs, Rick plans to make the designs public. For now, here's a sneak peek at the custom braking package partially assembled.

 

 

Rick gave us some technical details on the how and why of his design.

The design is modular and covers both the front and rear brakes. The outer bracket you see on the rear brakes is also used in the front. This is why there are 2 additional “outer brackets” (“L” shaped) in the part outlines [shown above].

 

 

This allows the mounting of front brake packages to the rear. Cobras are different than most production cars that the kit industry borrows parts from. Cobras have a typical front to rear weight balance of 55% - 45%. Additionally the center of gravity height is MUCH lower than a typical production car measuring approximately 15” in height. Also the tire Diameters remain quite large for such a low CG height. This means that this kit needs a lot more rear brake than the standard parts provide. My equations (not proven yet) should reduce the pedal force needed from around 150 lbs to about 40 lbs to lock all 4 wheels in a balanced manner (fronts locking slightly before the rears). I am working on another design very similar to this one, that would allow standard production 13” Mustang Cobra brake components to be used that would further reduce cost to builders.

 

And one more look at Rick's ride.

 

 

Note that when Rick ordered, he took advantage of our best tip for saving money on waterjet cutting: putting several designs into the same file. If you've got many parts all made from the same material and thickness, it's most cost effective to put them all into the same file before uploading them to the online quoting system.

Customer Bill Craig of Piretti Fine Putters wrote to show us where some of our waterjet cut parts ended up. In the photo above, you can see the custom golf club stand they made. Some of the parts came from Big Blue Saw, and Bill had the whole thing welded and assembled locally.

 

 

The parts shown in the CAD drawing above were created by Big Blue Saw from 0.25 inch thick aluminum 6061 using waterjet cutting. We applied Basic Finish before shipping. (It looks to me like Piretti applied another finish after final assembly to closer match the vertical bars.)

 

I don't know that we've ever created a golf club stand before this, but we have done a phone stand, as well as a medicine cabinet organizer.

If you want to show off YOUR sporting goods, why not take a look at our guide to Designing for Waterjet to get some ideas on how to turn your designs into a display stand using parts from Big Blue Saw.