Showing posts with label 3d printing with carbon fiber. Show all posts
Showing posts with label 3d printing with carbon fiber. Show all posts

Orbital Composites Advanced Carbon Fiber 3D Printing

Orbital Composites is a company which developed advanced carbon fiber and wire 3d printing with applications in space additive manufacturing. It should enable future missions to 3d print satellites and objects in orbit or to 3d print drones with carbon fiber structures.

Here is the interview with Orbital Composites Founder and CEO Cole Nielsen and presentation of their tech:



Orbital Composites homepage:

http://www.orbitalcomposites.com/


Coaxial extruder nozzle developed by Orbital Composites. It should deliver 10x increase in print speed. 

Coaxial extruder that can extrude carbon fiber,  plastic wire, solder epoxies and other materials.

Cosine AM1 industrial FDM 3d printer

Cosine AM 1 is powerful new 3d printer that is at home in industrial and professional production setting. It has large format, speed and ability to 3d print with many advanced materials including carbon fiber and metal powders.

Here are the technical specifications of their AM1 machine:
  • Build Volume:  1100mm * 850mm * 900mm
  • Accuracy:  .07mm per 200mm
  • Layer Resolution:  .1mm-1mm
  • Max Extruder Temperature:  450°C
  • Max Bed Temperature:  250°C
  • Max Chamber Temperature:  85°C
  • Nozzle Sizes:  .5mm, 1mm, 1.5mm
  • Max Flow Rate:  3.5 kg / 24hrs
  • Machine Weight:  700kg
  • Machine Size:  1650mm * 1400mm * 1600mm
  • Voltage:  100v-220v 50hz/60hz 3KVA
It can print with wide spectrum of materials:


NormalAdvancedAdditives
 PLA Polycarbonate Carbon Fiber, chopped
 ABS Nylon Carbon Fiber, continuous
 HIPS PBT Carbon Black, ESD
 PVA Acetal Glass Fiber
 PETG Stainless Steel Powder
 Bronze Powder
 Mica
 Glass spheres


Here you can see AM1 printing:




And here is AM1 printing in carbon fiber and polycarbonate:




Cosine Additive company page:

http://www.cosineadditive.com/






colorFabb XT-CF20 carbon fiber 3d printing filament

Dutch colorFabb just released their new carbon fiber 3d printing filament that gives new properties and deep matte black finish.

The print quality looks great but there are no independent tests or reviews







Here are the main features of XT-CF20 and technical specifications:
  • ColorFabb XT CF20 is a copolyester based carbon fiber composite material that is based on the unique Amphora 3D polymer from Eastman Chemical and is loaded with no less than 20% specially sourced carbon fibers suitable for 3D Printing.
  • Extreme High Flex Modulus (6.2 GPa) / twice as stiff as PLA
  • Moderate strain at break (8-10%), so no extreme brittle filament, butt toughness
  • High Glass Temp. (Tg = 80C)
  • Very high Melt strength
  • Very high Melt Viscosity
  • Good dimensional accuracy and stability
  • Low odor / Styrene Free solution
  • Easy processing on many platforms
  • High attractive matt black surface
  • Diameter Tolerance: ± 0.05 mm
  • Density: 1.370 g/cm3
  • Glass Transition Temperature: 75C
  • Price: 49,95 euro
One thing to keep in mind that this type of filament is abrasive and will wear out your brass nozzle much sooner then common thermopolymers, PLA, ABS and others. 

Here is a video presentation of XT-CF20:




Product page:

http://colorfabb.com/xt-cf20/

Space Weaver 3d prints ultra lightweight woven structures from carbon and fiberglass

Space Weaver isa DIY 3d printer that makes woven 3d structures from carbon fiber and fiberglass. The machine is based on hacked Shapeoko CNC and custom design gantry. It produces very light intricate structures that don't have any purpose now, but I could see than as ultralight antenna poles, decorative elements or even plant support. Area of carbon fiber and fiberglass DIY projects is just emerging and we could see much more practical applications and projects in the future.


  

From project description:
Space Weaver is a student-designed 3D weaving machine created by Prerna Auplish, Evan Bowman, and Ryan Chen at the California College of the Arts in San Francisco. The machine was created in the Digital Craft Lab (http://digitalcraft.cca.edu/) Creative Architecture Machines Advanced Studio with instructors Michael Shiloh and Jason Kelly Johnson of Future Cities Lab (http://www.future-cities-lab.net/).
Space Weaver is designed to create ultra-lightweight woven structures with fibrous materials. Using a 3-axis gantry system, woven forms are created in a similar process as most 3D printers, except they produce a significantly higher strength-to-weight ratio, result in zero waste, and require no support material. In short, Space Weaver is a seven foot tall 3D printer that uses carbon fiber and fiberglass to print five foot tall woven structures.
The project has been divided into three categories and their major components. These categories are:
  • Machine: frame and build plate, mechanical components, CNC gantry, electronics, and spools
  • Programming: TinyG and Grasshopper/Firefly scripts
  • Material Research: resin and fiber experiments 
  • Frame dimensions: 84” x 32” x 28”
  • Build plate dimensions: 17 ½” x 19 ½”
  • The majority of the frame was welded out of 60’ of 1” x 1” square tube carbon steel, with 1” flat bar mounting tabs. A steel frame is not necessary, however rigidity is very important for ensuring CNC accuracy. This machine has a relatively large Z-height (5’), and an exposed build plate (print bed). The exposed design of the build plate is based on the desire to emphasize the importance of the printed objects, as well as to provide ease of serviceability.
  • The build plate has its own smaller steel frame, with two routed ½” birch plywood sheets to hold a sheet of glass.

All the technical details, files, software and instructions to make this weaver yourself can be found at:

http://www.instructables.com/id/Space-Weaver-A-Seven-Foot-Tall-3D-Weaving-Machine/?ALLSTEPS

You can se video of Space Weaver weaving a structure here:

http://www.instructables.com/file/FCMKYZRI3PRHPB1/

For a professional desktop carbon fiber and fiberglass 3d printer look at Mark One.


Using carbon fiber and titanium 3d printing in production of Koenigsegg ultra performance sports cars





Christian von Koenigsegg explains how his company uses 3D printing in prototyping and production of amazing hypercars. They use it in everything from prototyping of car seats and foot rests to titanium 3d printed main structural car parts. Performances they achieve trough innovative technologies are incredible.

http://www.koenigsegg.com/























Their cars are real high-tech beasts. One:1 model has ratio of one horsepower per one kilogram.



Mark One carbon fiber 3d printer update and team members

Here is new video from Mark One team with them as main characters. They speak more about their printer, its properties and features, rigidity of carbon infused plastic parts, design process and vision ... nice one ...
They claim that models printed on Mark One can be used as fully functional parts due to carbon fiber enhanced properties.





Here is more detailed post about Mark One:

http://diy3dprinting.blogspot.com/2014/01/mark-one-first-carbon-fiber-3d-printer.html









Mark One first carbon fiber 3d printer

Carbon fiber 3d printing was the technology many people were waiting for. We could finaly get very durable and strong printed objects.




Technical specifications of Mark One:
  • Printing Technology: Fused Filament Fabrication (FFF) / Composite Filament Fabrication (CFF)
  • Build Size: 305mm x 160mm x 160mm (12″ x 6.25″ x 6.25″, 486ci)
  • Material Compatibility: Carbon Fiber, Fiberglass, Nylon, PLA
  • Highest Layer Resolution: FFF Printing: 100 Microns / CFF Printing: 200 Microns
  • Extruders: Dual Quick Change
  • Filament Sizes: FFF: 1.75mm, CFF: MF4
  • Pause / Resume Prints: Yes
  • Software: Cloud Enabled
  • Supported OS: Mac OS 10.7 Lion +, Win XP+, Linux*
  • Supported Browser: Chrome 30+, Firefox 10+, Safari 6+*
  • Supported Files: STL, .OBJ
  • Connectivity: WiFi, USB, SD Card
  • Price: at 5000 USD range

Mark One website has a following description of their machine:

Brilliant ideas need brilliant materials.
Designed to overcome the strength limitations of other 3D printed materials, the MarkForged Mark One 3D printer is the world’s first 3D printer designed to print composite materials. Now you can print parts, tooling, and fixtures with a higher strength-to-weight ratio than 6061-T6 Aluminum.

Gregory Mark, the President of MarkFoged, also co-owns Aeromation, another carbon high technology company responsible for manufacturing computer controlled race car wings. The wings are typically made out of carbon fiber because of it’s high durability, strength and low weight. They discovered that it is quite a challenging task to manufacture parts out of carbon fiber, because of the time needed and high expense in laying the fiber down piece by piece in the production process. That’s what motivated the development of 3D printer which could simply print the carbon material.

We are waiting for more details and print results!

Mark One is produced by Mark Forged:

http://markforged.com/the-specifications/

Now, after the initial hype, we can say that there are many uncertainties about the technology behind this printer.

  • carbon filament and various carbon fiber technologies have been used in 3d printers before, but as far as I know, no machine has been designed specially for the carbon technology and this would be the first desktop / prosumer printer
  • it is unknown how exactly Mark One prints with carbon fiber: is it a new "special" filament where carbon is mixed in thermoplastics or is it some other technology 
  • carbon fiber (and kevlar) wrapping 3d printed objects to reinforce them was tried before with good results, but it was done by hand: http://diy3dprinting.blogspot.com/2013/06/carbon-and-kevlar-fiber-reinforced-3d.html

Update (18.2.2014.):

here is new, more detailed, video about Mark One:

http://diy3dprinting.blogspot.com/2014/02/mark-one-carbon-fiber-3d-printer-update.html 


Screenshot of Mark One webpage showing that the carbon fiber material is 20 times stiffer then ABS and 5 times stronger

Mark One is multimaterial machine that can print objects with two materials with different combinations of core, shell and structural honeycomb 





















Update:

DIY carbon fiber and fiberglass projects are emerging:

http://diy3dprinting.blogspot.com/2014/12/space-weaver-3d-prints-ultra.html










Proto Pasta carbon, high temperature and polycarbonate alloy PLA / ABS filaments

Proto Pasta has some new filaments with enhanced properties then regular PLA / ABS.



Video from their Kickstarter:

Proto Pasta offers:

Carbon Fiber Reinforced PLA

Proto-Pasta Carbon Fiber reinforced PLA is made from NatureWorks 4043D PLA Resin compounded with 15% by weight Tenax short chopped Carbon Fibers. It is designed to be stiff, or to resist bending. It is the stiffest material we offer and makes parts with an incredibly solid feel. When printed, this material is a dark glossy black that glitters slightly in direct light from the fine chopped fibers reflecting the light.
Carbon Fiber Reinforced PLA does not require a heated bed and prints much like unreinforced PLA filament. The main difference is that it is brittle and care must be taken when handling the filament and loading the printer.
We have had good results printing at 190C-210C using a .5mm nozzle and direct-drive spring loaded pinch-roll style extrusion head. Layer adhesion is excellent and the material has low warpage.

High Temperature PLA

Proto-Pasta High Temperature PLA is made from a custom compound consisting of mineral filled impact modified PLA with a nucleating agent to help promote crystallization. Crystallization after printing is what gives this material added heat resistance. To fully realize this advantage, parts must be soaked in hot water or an oven after printing at 60C-80C for 3-5 minutes. This crystallizes the material and makes it much more heat resistant. It does not require a heated bed to print well, but this may help crystallize the material after printing and make oven soaking unnecessary for some parts. High Temperature PLA is a glossy off white, or very light gray. Printed parts look good and have slightly more texture than standard PLA. This material is not translucent like standard PLA.
We have had good results printing at 190C-210C using a .5mm nozzle and direct-drive spring loaded pinch-roll style extrusion head.
Layer adhesion is good and the material has low warpage.
Polycarbonate/ABS Alloy
Proto-Pasta Polycarbonate-ABS (PC-ABS) Alloy is an incredibly tough material designed for strong, resilient parts. When printed, PC-ABS is bright glossy white.
Proto-Pasta PC-ABS Alloy can print well. It is very moisture sensitive and even if stored bagged with desiccant, drying in an oven for ~ 1hr at 85C-95C may be required for bubble free high strength prints. Layer adhesion can be an issue if the part is large or the temperature is too low. We have had good success printing parts ~60mm long at 260C-280C using a .5mm nozzle and direct-drive spring loaded pinch-roll style extrusion head. A heated bed may help warpage and layer adhesion on larger/thicker parts.

Proto Pasta filament properties










They also offer Reusable filament Folding Spool



http://www.proto-pasta.com/

X-winder DIY carbon fiber wrapper or start of DIY carbon fiber 3d printing revolution

X-winder wraps carbon fiber with epoxy on rotating object. It lowers the price of carbon tubes and elements by up to 80% compared to market prices.

When you look at it from broader perspective it is a from of 3d printer which prints with carbon fiber, it just needs to be upgraded and developed to be able to print non-rotating shapes with full x/y/z movement or at least to reinforce ABS/PLA parts with carbon fiber applied on their surface.

There were similar solutions on the beginning of DIY 3d printing machines development like this 3d printer which printed silicone on rotating tube:

http://diy3dprinting.blogspot.com/2013/10/from-diy-3d-printing-history-1-silicone.html

There were successful applications of epoxy surface glued Kevlar and carbon fibers on regular ABS/PLA 3d printed parts which gave them amazing strength:

http://diy3dprinting.blogspot.com/2013/06/carbon-and-kevlar-fiber-reinforced-3d.html

For next level in carbon printing we need to bring those concepts in a single machine.
Hopefully there will be someone to develop this idea further.






X-winder kickstarter:

http://www.kickstarter.com/projects/1157143472/x-winder-the-worlds-first-desktop-filament-winder

X-winder home page:

http://xwinder.com/

X-winder PDF brochure:

http://www.xwinder.com/X-Winder_TriFold_Brochure.pdf
















X-winder technical specifications for standard 4 foot model and expanded 8 foot model 

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