Inspired by other wooden train track designs I decided to make my own.
I wanted a chamfer on all the pieces so that after printing I am not left with very sharp edges. After importing others designs in FreeCAD, I was not able to chamfer the .stl files successfully.
So, I made my own designs. With the help from http://www.woodenrailway.info/track/trackguide.html I got the exact dimensions for all the tracks.
Most tracks come with grooves on top and bottom so that for example curves are automatically a left and right curve.
Besides the standard track pieces there are also a few special pieces, like the outer curve track of a double track (Brio EE) piece.
Print the supports in a grid pattern with 25% fill. Distance x/y 1mm, distance z 0.15mm. 0.8mm shell, 0.75mm top/bottom.
I used PLA plastic and printed it really fast (top/bottom 50mm/s, outer shell 60mm/s, inner shell 70mm/s, infill 80mm/s) on high temperature (230 celsius). Works out great.
Step 1: Remove supports.
Yep. Remove the supports.
Step 2: Flame polish ugly white spots.
I used a small gas torch to flame polish the plastic where the supports were .
After removing the supports you get left with ugly white spots. A quick pass with the torch polishes the plastic. But do not over do it, or you are left with a warped or molten piece.
FreeCAD 3-way switch
FreeCAD parameter definition using spreadsheet.
Building in FreeCAD
I used FreeCAD to build the track pieces. First I defined all the design parameters in the spreadsheet. When sketching, I referred to the dimensions in the spreadsheet.
That way I could very quickly generate new track variants.
I only designed 1 curved track. Then used the spreadsheet to generate all curve variants. No more designing over and over.
I used FreeCAD to validate dimensional fitness. Using a H1 cross and 4 3-way pieces, you can make a large 4 way switch.