56 minutes ago, Zed Head said:

What material is AI?

Aluminum

AlSi10Mg if you want to get super technical on the specific alloy. Theres a few services that you can use to get parts printed in China. Ended up being $38 a cap (before shipping, tariffs, etc). I'll put more details in the thread I create once I take some pics.

One of the flaws of the English alphabet characters - AI (Artificial Intelligence) looks like Al (Aluminum). Thought you made a typo.

So, you're saying that now you can have metal parts fabricated in China and shipped to the US for a reasonable cost? Did you send them a file to work from? Is it printed or machined? Metal additive manufacturing?

Interested in how it turns out.

Found one -

https://www.xometry.com/capabilities/3d-printing-service/metal/

I'll go over the process in the new thread but I made my own model using CAD, 3D printed it out of PLA myself to test the shape and make sure I modeled the threads correctly, uploaded a file to craftcloud (i find they have better options than xometry), chose a material, chose a company, and then wait.

Its metal additive manufacturing though they did need to post process the threads with a cnc.

Craft cloud/xometry can also get you quotes for CNC and plastic 3D printing using filament that are pretty much unobtainable for hobbiests (PEEK, etc). For metal 3D printing, Al is by far the cheapest but they also have multiple grades of stainless steel, iron, titanium, and even super alloys like inconel.

Seems like the whole cap could be CNC machined from a block of aluminum or polymer. Interested in the results. Good luck.

1 hour ago, Zed Head said:

Seems like the whole cap could be CNC machined from a block of aluminum or polymer. Interested in the results. Good luck.

I already have them in hand and powdercoated.

Nylon or ABS should be able to hold up to the temp on the valve cover so I could've printed them at home but I used this as a test run of the 3D printing services. Also could've been CNC but for the specific geo of the cap, it wouldve been more expensive! I do plan on using the CNC options for something I'm designing for my subaru though.