Showing posts with label aluminum. Show all posts
Showing posts with label aluminum. Show all posts

Aluminum Profiles DIY 3D Printer by Thomas Workshop

I always like to see new 3D printer designs and builds by different people. Recently I found this larger volume (40cm3) machine by "Thomas Workshop" on Instructables. It is fully made from common aluminum profiles and Thomas did put some effort to document and present his work process.
Test prints look good and the frame seems sturdy.

























Here is the final video from three part series showing electronics and printing:




Here is the detailed step-by-step build guide with videos, documentation, and picture construction log:

https://www.instructables.com/id/3D-Printer-Working-Area-40x40x40cm/

Smartfriendz Smartalu 3D Printer

Smartfriendz from France have a new open source 3d printer design. It is the Smartalu based on aluminum frame and a large print area. It looks very sturdy.

Printer description:
Taking account of reprap evolution, we are sliding to all metal construction frames, bigger printable volume and better quality.
This printer is 27x26x25 cm printable size, with all modules made with 3mm aluminium lasercut and some printed parts.
The structure is still our 20x20 aluminium frame assembled with bosh torx 6x16 screws and drilled profiles. We can't find a better system to assemble a solid frame.

Smartalu in action:



All files and instructions to make it can be found at:

http://www.thingiverse.com/thing:1846437

http://smartfriendz.dozuki.com/

You can also buy it as a kit for 645 euro:

http://smartfriendz.com/en/





Aluminum Sand Casting 3D Printed Nose Ring

It's a nose ring. Get it? NOSE RING...
David Kent Watson 3d scanned his face, 3d printed his nose and used lost PLA casting to make it in aluminum. Cool project. I would wear that ring.

Here is the ring being sand casted:



Project homepage with much more details:

http://dkentwatson.com/art/the-nose-ring/



How to make a DIY injection molding machine from a drill press

If you want to make mass produced parts you will reach a limits of your 3d printed very quickly both technical and economical ones. For any serious mass production of plastic parts you must use injection molding which can be expensive in the beginning since the initial mold is costly but the parts are cheap afterwards.

Is there a middle ground? A device you can build yourself?
There is a possibility to make a DIY home workshop injection molding machine from a hacked press drill with Gingery attachment and a CNC milled metal mold.
You can use various types of thermoplastics like: PETE, HDPE, PVC, LDPE, PP, PS and ABS.

Scorch from Scorchworks documented his experience with it.

Here is a construction video of Gingery injection molding tool for a simple drill press:




Here is a demonstration of injection molding plastic parts into CNC milled molds:



For more info on his project see:

http://www.scorchworks.com/Injection_molding/injection_molding.html


For a simple DIY drill press injection molding apparatus you can check out this PDF guide:

http://rick.sparber.org/Articles/gpi.pdf


The setup:



Injection molded objects and the mold:



Make your own aluminum frame Ultimaker 2 clone

Jason developed Ultimaker 2 clone made with aluminum extrusion frame and 3d printed parts. According to his posts it work very well.

He describes it as:
This is not The Greatest UM2 Clone, no.
This is just a tribute.
This project began as a fun way to learn AutoDesk Fusion 360. I started by importing the entire Solidworks CAD file into a new Fusion 360 project, dropped the frame (walls) from the printer, built 20x20 Misumi aluminum extrusions to wrap the printer guts and then worked to build brackets to support all the parts that previously attached to the frame.
I've been printing nonstop on this new printer with the same precision and quality as my real UM2. In fact, I can use the same GCODE in either machine with identical results.



Video of this UM2 clone in action:



All the files and instructions can be found at:

http://www.thingiverse.com/thing:811271


Vulcanus V1 DIY 3d printer for under 300 Euro

New day, new machine project is published. Vulcanus was developed by 16 years old Vulcaman. Nice work mate!



Technical specifications:
  • Based on CoreXY
  • Aluminum extrusions frame
  • Dimensions: 44cm x 44cm x 60cm
  • Build Volume: 20cm x 20cm X 26cm
  • Print Speed: 300mm/s tested but you can also try higher values
  • Resolution: up to 0.05mm
  • Electronics: Ramps 1.4 with TMC2100 1/256 microstep motor driver, Arduino Mega 2560
  • Updates coming soon: 32bit electronics, enclosed build chamber
  • Price: under 300 Euro depending on your preferred source
Detailed build instructions can be found at:

http://www.instructables.com/id/Vulcanus-V1-3D-Printer/

3d printed parts:

http://www.thingiverse.com/thing:821066

Update:

Vulcaman developed a much cheaper 60 euro Cherry 3d printer:

http://diy3dprinting.blogspot.com/2015/06/cherry-3d-printer-can-be-built-for-60.html


How to use inductive distance sensor and Mk3 aluminum hotbed for automatic bed leveling

3D Proto, creator of dual parking extruder, made an excellent video about how to install and use inductive distance sensor with Mk3 aluminum hot bed. This combination enables you to reach much better quality of ABS prints. With inductive distance sensor bed leveling you can:
  • Save lot of time by not having to have to mess with springs and screws on your print bed. Run the auto leveling routine before every print or just one time for each start-up of the printer.
  • Less issues related to non level print beds like parts coming up on one corner and nozzles jamming because the print started too close.
Inductive distance sensors are very cheap so it makes me wonder why are they not used by more 3d printers for automatic bed leveling?
If you wont to see full guide on how to install and use it with Marlin go to:

http://www.instructables.com/id/Enable-Auto-Leveling-for-your-3D-Printer-Marlin-Fi/

Inductive distance sensor on the extruder paired to Marlin firmware constantly corrects the distance to print surface

Diagram showing how to connect inductive distance sensor to control unit ie. Ramps

Combined with Mk3 Alu heated bed gives much better ABS prints like in this example where you can see very strait walls




Here is the video guide:



Source: http://3d-proto.de/

High grade aluminum DIY syringe extruder by Liam Gilbertson

DIY syringe pumps and other syringe devices are used in different 3d printing projects for depositing various materials from living cells to solder paste dispensers.
Liam Gilbertson posted a very detailed tutorial on how to build your own syringe extrude from MendelMax 2.0 or any other 3D printer based on 2020 extrusion rails.
Be aware that this is not a novice level project since the extruder is very sturdy and may require some machining knowledge and more specialized tools like laser or water jet cutter able to cut 3mm aluminum.










Step-by-step build guide, all the files and code can be found here:

http://www.instructables.com/id/Build-a-Syringe-Extruder-for-your-MendelMax-20/

GitHub repository: https://github.com/LiamGilbertson/MM2SE


MOLDLAY filament for DIY lost wax casting with 3d printed objects

Kai Parthy, well known filament material developer, has a new product named MOLDLAY which is a thermoplastic filament with properties similar to wax. It can be used for two casting techniques: lost mold (lost wax casting) or permanent mold casting.
Lost PLA casting is well known method and you can  use microwave oven lost PLA casting, but MOLDLAY can be melted in a common baking oven due to its low melting point and wax like properties.













Here are the key features and technical data:

  • superior dimensional stability
  • tiff, rigid at room temperature
  • near zero warp
  • printable without heated bed
  • print at 170 – 180° C,
  • heated bed max. 40°C,
  • melting temperature ~ 270°C 
  • the molten wax flows freely out the mold, similar to liquid paraffin
  • price: unknown
  • contact for dealers: kp@cc-products.de

Here is a video showing the entire process of lost wax casting with MOLDLAY:





Using home microwave for lost PLA 3d printed aluminum parts

Lost PLA is method used to produce cement molds for metal casting and it is used mostly with molten aluminum. Desired object is 3d printed in PLA, cast is made around it and the PLA is melted away. The mold is then used for metal casting. Entire process is usually done with a propane gas powered kiln or smelter, and this project used home microwave oven.

The process is simple but you will need to take safety seriously. Object 3d printed in PLA is coated with susceptor that transforms microwaves into heat. Susceptor is made from mixture of silicon carbide, sugar, water, and alcohol. The part is then placed in a mold made of plaster of paris with perlite and heated in an unmodified household microwave to burn out the PLA.
A second microwave with a top emitter is used to melt aluminum, which is then poured into the prepared mold. When the metal cools down, the mold is broken to take out the metal part for post-processing



























From project description:
Our system uses consumer microwave units to perform burn-out of PLA from molds, and a second microwave to liquify aluminium, to be poured into the mold. 3d printer inspired mechanics will move the aluminium from the microwave, into the target mold under human control across the network, so that there is no risk to the person operating the machine.
What is working and what we're working towards:
What works now is that we are able to successfully melt aluminum inside a microwave and supply our molds to get fine quality crafted aluminium parts.
The vision is to automate the process and build machines so that the system can be remotely run by a human being safely from their terminal.
Automation will be as simple as two to three machines powered by arduino with minimum axes.

One machine will be a forklift to pickup the item and deposit it safely onto a pair of fire bricks. One is a crane to pickup the top from the kiln, and one is a combination of forklift and a x,y table. This will pickup the cup, place over target, and pour through a heated steel funnel into the mold.
Ideally, we see an operator walking to the machine, starting the microwave on the mold & aluminium. When notified the machine is done, the operator can use gloves to pickup and bury the mold in sand, then walk back to their workstation, and pour the aluminum remotely. This will reduce the risk of injury to an operator to near 0, and not require any dangerous gasses to perform the melt.
All of the software will be released under the GNU GPL V3 as the project advances, with the hardware designs released under the TAPR OHL.

Detailed project page and build log on hackaday.io:

http://hackaday.io/project/2434-microwave-aluminium-printing

Project homepage:

http://fosscar.faikvm.com/trac/wiki/LostPLA


UPDATE:

Here is very detailed video presentation by Julia Longtin on Chaos Computer Club 31th Chaos Communication Congress. It is a great how-to guide on casting high quality 6040 aluminum pieces using a 3D printer and commercially available consumer microwaves



Here is a more detailed guide on how to make and use microwave oven DIY smelter for silver or tin solder:

http://www.instructables.com/id/microwave-smelter/?ALLSTEPS





Here is a different approach to melting aluminum in a microwave oven:



Rat Rig produces first European aluminum V-slot linear rail




Rat Rig is Portuguese company that targets DIY, hobby and prosumer hardware market. They just announced that they are now first manufacturer of aluminum linear v-slot rails. They are priced in 6 euro per meter price range.

I don't have much experience in using v-slots, but it is good to know that they are now more available in my part of the world, Europe.

http://ratrig.com/

V-slot product page: http://ratrig.com/hardware/vslot.html




























New method of DIY 3d printing aluminum with alumina wet paste extrusion

Italian WASP is experimenting with new method to 3d print in aluminum. It uses wet mixture of alumina (Aluminium Oxide Al2O3)  extruded trough syringe extruder.
Alumina powder is mixed in different mixtures with water, denatured alcohol and glycerin and deposited on print surface.
After drying it can be heated to 1300/1500 Celsius to harden it.

























More information is needed but it could work ...

Source, in Italian (use google translate):

http://www.wasproject.it/w/2014/06/3d-printing-allumina/


BuildersBot 3d printer and CNC hybrid with welded steel frame

BuildersBot is new 3d printer / CNC hybrid with welded steel frame and big print volume.



Here is video overview of the machine itself and the main technical specs:



It has strong stainless steel MIG welded frame with aluminum rails which is the main fueature. It is controlled by Arduino Mega and a ramps 1.4 board. 3D printing volume is big at 500X600X200. Power is provided by four Nema 23 motors, and on the working end there are 0.5mm J-head and Kress 1050 Spindle MFE for CNC.
BuildersBot is developed by Aldric Negrier.


Construction guide and more details can be found at:

http://www.instructables.com/id/Arduino-Controlled-CNC-3D-Printer/?ALLSTEPS



How to make low cost linear actuators for your 3d printer or CNC machine




Lukas Hoppe made this tutorial and designed components that can be 3d printed or lasercut to make cheap DIY linear actuators. It is a set of brackets and endblocks to mount NEMA 17 (or other motors with adapters) motors on linear rails. The result look good.
You can always rely on that German engineering. Gut gemacht Lukas! Danke fur dieses projekt.

Guide and all STL files can be found at:

http://www.instructables.com/id/Low-cost-linear-actuator/?ALLSTEPS



DIY electric coffee maker and cold brew machine made with help of 3d printing




























Here is a cool DIY project that guides you step-by-step in making your own fully functional electric coffee maker. I LOVE COFFEE!

It uses 3d printed parts as external structure and for lost PLA casting of aluminum parts. Hey, no one said it will be easy: if you want to do it yourself you will need to melt and cast aluminum. Stay safe kids.

Detailed instructions how to put it together are at:

http://www.instructables.com/id/Electric-Coffee-Maker/?ALLSTEPS

All the files can be found at:

http://www.thingiverse.com/thing:348199


To learn more about lost PLA aluminum casting take a look at:

http://diy3dprinting.blogspot.com/2014/04/photo-buildlog-on-how-to-cast-metal.html

Detailed video guide: http://diy3dprinting.blogspot.com/2013/05/3d-printing-and-metal-casting-tutorial.html


You can also make a much simpler non.electric drip cold brew setup developed by Jonathan Odom:




Here is the guide for DIY cold brew coffee maker:

http://makezine.com/2015/07/27/3d-print-elegant-cold-brew-coffee-maker/

http://www.instructables.com/id/Coffee-Cold-Brewer/?ALLSTEPS




Lix - the smallest 3d drawing pen




Lix is the new 3d drawing pen with elegant aluminum body with small size. It is almost the same size as simple ball pen. It can be powered by USB port and you can carry it with you everywhere. Both ABS and PLA fulament can be used to create 3d drawings.

The pen will be launched on Kickstarter for $139.95 USD soon.

http://lixpen.com/


Lix vs 3Doodler (or any other 3d drawing pen currently available)




Lix 3d drawing pen technical specifications

Update (1.5.2014.):

Lix is no on Kickstarter and it is raising a LOT of money:

https://www.kickstarter.com/projects/lix3d/lix-the-smallest-3d-printing-pen-in-the-world





Update 2 (3.5.2014.):

There is an article on hackaday about can Lix actually work because USB does not provide enough power:

http://hackaday.com/2014/05/03/ask-hackaday-can-the-lix-3d-printing-pen-actually-work/

Update 3 (23.5.2014.):

Surprise, surprise: Lix is in problems:
LIX appears to have entered into the start of their Kickstarter campaign with an idea, and a very basic prototype. Their business plan seems to be changing and evolving based on two main factors. One is feedback from their backers, and the other is the huge demand that they have unexpectedly received for their future product.
LIX has announced that they are going to be hiring an engineering company to work on the newest prototype of the pen. The engineering firm that is being assigned to this project, will need more time in order to create a high quality product. They expect to have to redesign some of the aspects of the LIX Pen, to prepare it for mass-production.
They also changed their shipment schedule and postponed the dates ... good luck to the backers ...

Source: http://3dprint.com/4281/lix-3d-pen-problems/




Tiny homemade 3d printer from Germany

Just a printer I found on one German website. Homemade and undocumented. I like the aesthetics of the design ... it looks ... well ... German ... shiny aluminum and wires ... just cool ...




more details will be available soon ...

Update(20.2.2014.):

Tiny now has a heated bed milled out of aluminum. Heating is done by 6x 12V/40W heating cartridges as they are now often used in hotends. Dimensions are 100 x 80mm, the thermistor is immersed directly in the middle.





























http://www.datensucht.de/2014/02/19/3d-drucker-tiny-das-heizbett/

I contacted, the maker, Thomas and asked him is he going to open source the design, he answered:
Not sure about open sourcing it yet. Not that I don’t want to make it open, but a lot of parts where made on the fly without proper CAD modeling.
But I’m planing to swap the wood milled parts for aluminum ones as soon as the design proves to work for a few months, maybe I’ll create proper files then and publish them.
If anyone wants to build it and needs specific measures or information on the printer I’m happy to help out.

Tiny homepage in German:

http://www.datensucht.de/2014/02/17/neuer-3d-drucker-im-haus-tiny/

Printrbot introduces new full metal Simple 3d printer

Printrbot is well known for its low cost plywood printers. Over at Makezine there is a news that they are releasing the first full metal body machine, the metal Simple. It has larger print volume of  6″x 6″x 6″, Z-axis end-stop adjustment knob and a self-leveling bed. It looks good, and should be very sturdy.

























Here is video presentation of metal Printrbot Simple by Brook Drumm:





Here is video of metal Simple printing:





Here it is on floor of 3D Printshow in NY




http://printrbot.com/

Printrbot metal Simple technical specifications:

  • Price: not available 
  • Release Date: 2014
  • Build Volume: 6″ x 6″ x 6″ (150mm x 150mm x 150mm)
  • Print Resolution: 100 Microns
  • Filament: 1.75 PLA
  • Hot End: 1.75 Ubis Hot End with 0.4mm Nozzle
  • Construction: Steel and Aluminum Body
  • Finish: Powder Coated
  • Print Bed: Semi-Auto Leveling via Software
  • Belt: GT2
  • Pulley: Aluminum
  • Rods: 12mm
  • Product Weight: 8 lbs
  • Print Software: Compatible with Repetier Host and Pronterface

Update (1.3.2014.):

Printrbot just presented new Printrbot Go! v2 larger volume 3d printer:

http://diy3dprinting.blogspot.com/2014/03/printrbot-go-v2-larger-3d-printer.html


Update 2 (20.3.2014.):

Here is Brook explaining evolution of Printrbot from previous designs with many parts to metal body with only five major parts.





Source:

http://makezine.com/2014/02/11/first-look-printrbot-unveils-its-all-metal-3d-printer/

Update on Vader molten aluminum DIY metal 3d printer - now debugging with gallium




Vader is under development, now they are testing the printhead with gallium which melts at low temperatures (30 C) and then they will continue with molten aluminum (at 800 C).

Introduction to Vader:


http://diy3dprinting.blogspot.com/2013/10/vader-diy-3d-printing-with-molten.html

They also released mock-up of their Mark 1 unit:

The Mark I will be the first production machine. It will be built in very low volumes and sold to technically capable development customers who will help us improve the product,. With the lessons learned from development, the company will create the mass production successor.

Estimated Sale Price: $400,000
Estimated Release Date: Q1-Q2 2014


















Cartesio 3d printer

Cartesio is sturdy 3d printer / desktop cnc design by Jos Scheepers with aluminum frame that you can buy or build yourself. It comes in two sizes: bigger Cartesio W and smaller Cartesio M.

Cartesio W description from the project page, it is priced at 2099 euro (Cartesio M is priced at 1699 euro):
The CartesioW V0.9 has a massive build volume of 400x200x200mm and comes standard with a 3D print extruder and a large Heated buildplatform
If you want other tools (engravers, plotters,...), please select them in the Tools catagory.
The Lead time for this product is currently : 3-6 weeks after payment has been received
We can also assemble Cartesio for you.
  • Cartesio is a feature rich profesional CNC router.
  • It supports a wide range of tools ig. 3D-print extruder and engraver.
  • It is possible to print multiple colors, or materials.
  • unique features :
  • quiet printing
  • very rigid build platform which does not move in X,Y direction.
  • high precision GTM (gantry tool movement)
  • automatic printhead cleaning
  • large build volume of 400x200x200mm (X,Y,Z) M(edium)
  • printable upgrades
  • optional engraving tool with software speed control
  • CDC (cable drag chains) cable protection

other features:
  • stand alone printing
  • moveable, due to its rigid design
  • prints small and large detailed objects
  • prints rigid construction elements
  • high speed printing






http://reprap.org/wiki/Cartesio

Project homepage:

http://www.mauk.cc/

Cartesio wiki and building instructions:

http://www.mauk.cc/service.html

You can alos find them on Thingivers under:

http://www.thingiverse.com/jos/designs

http://www.thingiverse.com/thing:21664




CartesioW and smaller CartesioM comparison 

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