Train freight car for OS-Railway - fully 3D-printable railway system! by Depronized

Last crawled date: 3 years ago

OS-Railway is a complete railway kit designed from the ground up to be fully 3D-printable! Everything from track, switches, locomotives and cars and accessories are specially designed to be printable.
Note! this is the first version, I apologize in advance if not everything fits together perfect, I have printed and built one and it works so don't hesitate to ask in the comments if you have any questions!
Update 27/6/2017 Added a shorter version of the chassis on request, the short version is 195mm. The orientation of the holes in respect of the boogies are still the same, although other things like hopper car addon and other stuff made for the longer chassis will of course not work with this one.
Update 7/4/2017 I changed the coupling to a new simpler but more rigid version. It is a simpler coupler than the one made by gfrantz so if you want the most scale like, click on the link below.
Scale coupler Click on the following link for a scale like coupling mechanism made by gfranz: http://www.thingiverse.com/thing:2196463
Update! gfrantz has made some nice doors for the container, you can find them here: http://www.thingiverse.com/thing:2159257
Container stand: http://www.thingiverse.com/thing:2179125
This is the page for freight car, please see separate pages for tracks, locomotives and more.
Tracks: http://www.thingiverse.com/thing:2146361
This is the first version of the freight car. It is made to be a flexible chassi platform with several M2 holes distributed over the chassi in order for you to mount different structures on top. In the pictures I just placed a 20 foot ISO container on it for visual reference. I will make more fastening elements and other things for this car although I prioritize the track system now when this car is functional. Check this page now and then to see updates. I will not change the chassi so you will be able do download and mount upgrades later on if you print and assemble the chassi now.
What you need:
8pcs ball bearings 6mm OD 3mm ID and 2,5mm W. (I will use these as standard).
4pcs wheel shafts, 42mm lenght, 3mm thickness. I used carbon fiber rod
8pcs M2x8-10 (between 8 and 10mm, not critical which) (absolut max 12mm)
4pcs M3x10 hex (these keep the car holder in place in the middle of the bogie, therefore their heads cannot be too wide. The car holder needs to rotate freely so that the train car can cope with vertical radius for bridges, so don't set them tight.)
2pcs M3x10-12 to attach the bogies to the chassi. I designed the chassi with room for a nut, but when I mounted the car I realized that the screw set so tight without so there is no need for the nut. Without nut you can use M3x10, if you want to use a nut, you need M3x12.
2pcs M3x10 to attach couplers.
2pcs M1,6x5-6 for the coupler assembly (if you only have longer ones, don't worry, they are easy to cut off.)
Notes on printing and assmbly

The chassi is made to be printed upside-down. That is why there is a chamfer angle to the side details to avoid the need for support. Note, there can be a bit trouble with the room for the bogie nuts, so if you intend to use such, you can enable support from build plate so that this space is printed nice and clean.


Ballbearings To mount the ballbearings in the bogie sides, a good way is to use a vice. It's a very tight fit and is supposed to be. You can trim the edges a bit so it's easier to guide the ball bearing right.


Orientation on print bed Take a look at the image showing all the parts on the build plate, NOTE! I do not recommend that you print all at once like this, I always print a couple of parts at a time to avoid loosing a whole batch if something goes wrong. This pictures is only intended to show you the orientation the parts should have on the build plate for best result.


Bogie sides require a tight fit to the hub, use a knife to trim the edges if it doesn't fit perfect. If you mount the sides and they don't fit perfect, your wheel shafts will not align and all wheels will not touch the track.


The included container is just a modified old CAD-file for reference, just to have something to put on the chassi. It doesn't print perfect and lack doors, but I include it anyway as it's in the pictures.

The coupler system has been designed after the Z70 locomotive was published. If you printed the first version, don't worry, the only thing you need is a 3mm hole on the underside on the back to attach a screw to mount the coupler arm. Place it center, roughly 4-5mm in (it's not critical a mm here or there doesn't matter). Only make sure that you don't drill all the way into your sevo if you have mounted one (I did...). The coupler has a 4mm hole but stil use a 3mm screw, this is intentional to give the coupler a bit of freedom of movement.