Showing posts with label diy 3d metal printer. Show all posts
Showing posts with label diy 3d metal printer. Show all posts

Desktop Metal 3D Printing with Microwave Enhanced Sintering

Here is another revolutionary step forward in 3D printing: the desktop metal 3d printer. It deposits metal "paste" made from metal powder with a polymer binder in a similar way as any common FDM machine and the parts are then sintered in a microwave enhanced furnace chamber.
The price is comparable to higher-end professional FDM machine from a few years ago. They also sell production cell that has much higher capacity for more demanding production facilities.


Tech specs:

  •  Build volume: 12 in x 8 in x 8 in (305 mm x 205 mm x 205 mm)
  •  Materials:  Steel, Titanium, Aluminum, Copper and other undisclosed materials
  •  Layer height: 50 μm (minimum)
  •  Dimensions: 60 in x 49 in x 30 in (1500 mm x 1250 mm x 750 mm)
  •  Technology: Microwave Enhanced Sintering
  •  Price: $120,000 for the desktop version, $250,000+ for manufacturing cell production system


Desktop Metal presentation video:




Here is a much more in-depth video by GoEngineer with many details about the machines, materials, and the process:




Company homepage:

https://www.desktopmetal.com/



Electrical Discharge Machining DIY Attachment for Your 3D Printer

ArduinoVersusEvil developed a DIY EDM attachment for a standard DIY 3d printer. EDM is described as:

Electrical discharge machining (EDM), sometimes colloquially also referred to as spark machining, spark eroding, burning, die sinking, wire burning or wire erosion, is a manufacturing process whereby a desired shape is obtained using electrical discharges (sparks). 
Material is removed from the workpiece by a series of rapidly recurring current discharges between two electrodes, separated by a dielectric liquid and subject to an electric voltage. One of the electrodes is called the tool-electrode, or simply the "tool" or "electrode", while the other is called the workpiece-electrode, or "workpiece".
It opens the whole new are of metal machining on a regular small desktop 3d printer.The developer has not yet released the plans but there are many DIY EDM solutions around that could be customized. Google is your friend :-)

Here are videos of EDM attachment in action and some rough results:







RepRapWiki has a great compilation with several DIY projects and detailed description of key concepts:

http://reprap.org/wiki/Electrical_Discharge_Machining

Wikipedia article with technology overview:

https://en.wikipedia.org/wiki/Electrical_discharge_machining

Source article with more details about this project:

http://makezine.com/2015/06/18/vaporize-metal-3d-printer-mod/


Standard EDM toolhead



Mini Metal Maker is ready to go to production

Mini Metal Maker is a small metal clay 3d printer developed by David and Lindsay Hartkop. It extrudes special metal clay which is then air dried and fired in a kiln to get metal objects. Ideal for jewelry makers and other small fine metal specialists.
The first version of Mini Metal Maker had a very successful Indiegogo campaign in 2013. Now the new version if fully matured and is on Indiegogo again to move the production of the machines from their home to real factory..
They have developed it from a wooden proof-of-concept to a sturdy production-ready machine ready for this specific metal clay 3d printing market.

Technical specifications:
  • the print bed currently allows for prints up to a 3.15 in cube (8 x 8 x 8 cm)
  • XY resolution: 10 microns
  • Z resolution: 2 microns
  • Extrusion resolution: 250 micron traces with 22 ga. nozzle
  • The device prints with a commercially available jewelry product known as "metal clay." This material is a pre-mixed emulsion of metal particles in a water soluble organic binder. When heated to 1550˚F(600˚C-900˚C) in a kiln, the binder burns away as the metal particles fuse together.
  • The Mini Metal Maker measures 9 in wide, 12 in deep, and 18 in tall (23 cm x 30 cm x 46 cm) 
  • Electronics / software: Arduino Duo with modified open source Sprinter firmware
  • USB port
  • Price: starting from 2100 USD on Indiegogo






















Bronze metal parts for ReRap Wades extruder












Here is a well produced presentation video:



Go and check their Indigogo campaign:

Postprocessing copperFill and bronzeFill filament 3d printed objects to make them shine

Adafruit released a guide on how to effectively polish copperFill and bronzeFill filament 3d printed objects and get them to high shine. They use some simple machines and it the results look easy to reproduce. After the process the objects look like they were casted in full metal.
The main part of the polishing is tumbling the prints in a container with brass screws



Full guide is on Adafruit learning system:

https://learn.adafruit.com/copperfill-filament



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:



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/


Molten3D TIG welding DIY metal 3d printer by Steve Delaire

Here is new DIY 3d metal printer based on a TIG welding  (Tungsten Inert Gas) process created by Steve Delaire. It is still under development but the project is very interesting as is any attempt to make homemade fully functional metal 3d printer.





It uses cheep standard MIG steel wire you can buy anywhere, it maybe even cheaper then the plastic filament.



























The output objects are still very rough shapes but the technology is advancing. TIG molten wire is more similar to water then molten plastics, it creates beads so continuous fine layers are much harder to achieve.

Print results from Steves blog. Still very basic but I'm sure he will improve it. 

Project homepage with much more information:

http://molten3d.blogspot.com/


We have seen similar concept based on MIG welder and inverse Delta kinematics:

http://diy3dprinting.blogspot.com/2014/02/open-source-diy-metal-3d-printer-made.html


MX3D Metal supportless multiaxis 3d printing




Industrial robot arm with attached advanced welding head. It can print lines of steel, stainless steel, aluminum, bronze or copper "in mid-air."
It's developed by Joris Laarman Lab in collaboration with the Institute for Advanced Architecture of Catalonia (IAAC).
MX3D Metal evolved from this project where they used thermosetting polymers only:

http://diy3dprinting.blogspot.com/2013/05/mataerial-thermosetting-polymers-3d.html






















Source:

http://www.core77.com/blog/digital_fabrication/joris_laarmans_latest_anti-gravity_3d_printer_basically_conjures_metal_out_of_thin_air_26474.asp


Chipfuzer V 2.0 of arc welder based DIY metal 3d printer

Mark Miller developed second version of his arc welder based metal 3d printer - here is the Chipfuzer V2.0.




Mark wrote:
Chipfuzer 3 D metal printer (version 2.0). This is the second prototype I made to improve the original design. It is smaller-12 inches wide, 12 inches deep and 12 3/4 inches tall. This model is fully enclosed and has safety features to keep the user safe from high voltage and harsh arc light produced on the build table.
The design also fully eliminates RFI produced by the arc process and makes a neat, tidy compact unit that can be easily transported and used anywhere.
The multicolored enclosure components are due to just having a little bit of each color paint in several cans on the shelf (low funds) and not representative of anything, or me trying to be overly "artsy".
I scaled down the X,Y and Z slide mechanisms but kept the build table the same as the first model, and the build size is nearly the same as the original. I am still tinkering with it a bit, but satisfied thus far with the new design.
This machine went together better and faster than the original, despite having to scavenger hunt parts, and make due with similar materials. In some places the unit is triple insulated, and the interior is covered in conductive coating and grounded. I think one more design and build will probably get me to a really good design for this idea, and will concentrate more on the software end of things from now on. Thus far I have made about a dozen prints with this, but plan on using this machine for most future experimenting.

First post about Chipfuzer:

http://diy3dprinting.blogspot.com/2013/11/chipfuzer-diy-3d-metal-printer-by-mark.html


Chipfuzer V 2.0 - you can see the print chamber and arc welder tips

Open source DIY metal 3d printer made with MIG welder




This is important step forward for the entire field: open source sub 1500 USD metal printer. It can be mad by anyone with some experience. It is based on static MIG welder and moving invert delta 3d printer platform as build bed.

Project was developed by Michigan Tech's Open Sustainability Technology Lab: Gerald C. Anzalone, Chenlong Zhang, Bas Wijnen, Paul G. Sanders and Joshua M. Pearce. Kudos to you gentlemen!


From project abstract:
Technical progress in the open-source self replicating rapid prototyper (RepRap) community has enabled a distributed form of additive manufacturing to expand rapidly using polymer-based materials. However, the lack of an open-source metal alternative and the high capital costs and slow throughput of proprietary commercialized metal 3-D printers has severely restricted their deployment. The applications of commercialized metal 3-D printers are limited to only rapid prototyping and expensive finished products. This severely restricts the access of the technology for small and medium enterprises, the developing world and for use in laboratories. This paper reports on the development of a <$2000 open-source metal 3-D printer. The metal 3-D printer is controlled with an open-source micro-controller and is a combination of a low-cost commercial gas-metal arc welder and a derivative of the Rostock, a deltabot RepRap. The bill of materials, electrical and mechanical design schematics, and basic construction and operating procedures are provided. A preliminary technical analysis of the properties of the 3-D printer and the resultant steel products are performed. The results of printing customized functional metal parts are discussed and conclusions are drawn about the potential for the technology and the future work necessary for the mass distribution of this technology.

Project homepage with detailed build instructions:

http://www.appropedia.org/Open-source_metal_3-D_printer

Academia paper on this printer:

https://www.academia.edu/5327317/A_Low-Cost_Open-Source_Metal_3-D_Printer

If you want to learn more about MIG (metal inert gas) welding:

http://en.wikipedia.org/wiki/Gas_metal_arc_welding

















































There is another welder based DIY metal 3d printer project with almost no documentation - The Chipfuzer:

http://diy3dprinting.blogspot.com/2013/11/chipfuzer-diy-3d-metal-printer-by-mark.html

Update (19.6.2014.):

New TIG welder based metal printer:

http://diy3dprinting.blogspot.com/2014/06/tig-welding-diy-metal-3d-printer-by.html

Mini Metal Maker DIY metal clay 3d printer




Mini Metal Maker is small DIY 3d printer that prints objects suitable for jewelry production, watchmaking and small gears modeling,  small pistons and generally small metal parts. It uses precious metal clay that needs to be put in a high temperature kiln in order to get into metallic form. it will not make "regular" sized hard metal parts. It is more oriented towards craftsman and artisans.

From the Mini Metal Maker page:
The impact


The Mini Metal Maker is a game-changer in the world of do-it-yourself 3-D printing. It gives engineers and designers a new tool for fabricating precision parts without expensive machinery or difficult manual processes. It puts a powerful new tool in the hands of artists and craftsmen for creating customized repeatable items in metal. It is also a valuable and accessible educational tool because it is low cost and small enough to be portable.

I've always dreamed of being able to print miniature parts and detailed sculptures directly in metal. To me, the Mini Metal Maker moves 3D printing from the land of plastic toys into the real world of arts, science, and engineering. I have had so much fun creating and using the Mini Metal Maker, and believe that you will too. 

Other Ways You Can Help

Your words are precious to us. If you can not contribute, or if you simply wish to help another way, please like us on Facebook, share our website with your friends, and spread the word about the Mini Metal Maker to anyone who might be interested.
FAQ
What is the Mini Metal Maker for?
The Mini Metal Maker is for printing custom jewelry such as rings and gem settings, sculptures, specialized machine parts, ornamental hardware, metal chains, or even special hardware such as miniature turbines or pistons.

Who will use the Mini Metal Maker?
The Mini Metal Maker is for anyone interested in creating small detailed metal objects. This includes the 3D Maker community and as jewelry artisans. The Mini Metal Maker is also a valuable tool for design engineers and machinists, who require small runs of specialized hardware for creating prototypes. The Mini Metal Maker adds new capability for the DIY inventor or artist by making fabrication in metal easy and direct.

What's the print bed size?
The print bed currently allows for prints up to 2.3 inches x 2.3 inches x 2.3 inches (6 cm x 6 cm x 6 cm) in size. The movement resolution is up to 1600 steps/mm.

How does the clay become metal?
The device prints with a commercially available jewelry product known as "metal clay." This material is a pre-mixed emulsion of metal particles in a water soluble organic binder. When heated in a kiln (600˚C-900˚C) the binder burns away as the metal particles fuse together.

Where can I buy materials for the printer?

I have been purchasing various metal clay materials online from Amazon and also through e-bay. The Mini Metal Maker requires the clay to be precisely mixed to a special consistency. I will provide pre-mixed syringes of clay along with the parts and software for the MiniMetalMaker.

Can I use it with other clays, or just metal clay?
The mini metal maker will work for most water soluble clay or ceramic type materials if the consistency of the material is properly mixed. Refining this mixing process for each of the available types of clay is an important part of the research and development we are currently completing. Since the device extrudes from commercially available syringes, it is entirely possible for users to develop their own clay blends. We will make pre-mixed clays of different varieties available for sale along with the Mini Metal Maker.

How big is the printer?

Our current printer measures 16 inches (41 cm) tall, 7 inches (18 cm) wide, and 12 inches (30 cm) deep. The new prototype will be slightly deeper in order to accommodate bed motion for two heads in place of just one.

Will it work with Windows 8? How about Macintosh?
Yes, and Yes. The core computer for the Mini Metal Maker is an Arduino Duo running modified Sprinter-based open source firmware. We are developing a cross-platform work environment for loading your objects into the printer.

Do you always need a computer to print?
No. It will be able to print directly from SD cards. Our current prototype requires a connection to a computer, but we are designing the production model to print directly from a compact flash chip that is inserted into the machine.

Does it work with a USB port?

Yes it does. It just has a standard printer-type USB cord that you could pull out of the back of your normal printer and connect to this printer.

Does it cause indoor air pollution or health problems for users?
No. The Mini Metal Maker does not cause any fumes or air pollution. The clay is water based and non-toxic, as its original purpose was for sculpting by hand. Also, the entire machine operates at room temperature because it does not have to melt plastic. You will need to purchase a small *kiln, however, in order to fire the objects.

*Kilns of any sort should be located in a well ventilated area away, often in a garage or a covered outdoor work area.
Mini Metal Maker homepage, detailed build files should be available there in the future:

http://www.minimetalmaker.com/

They had very successful Indiegogo campaign, hopefully they will release the plans as planed:

http://www.indiegogo.com/projects/minimetalmaker-a-small-3d-printer-that-fabricates-with-metal-clay



























Take a look at Newton 3d, printer based on same technology:

http://diy3dprinting.blogspot.com/2014/02/newton-3d-diy-metal-clay-3d-printer.html

Update:

In 2015 this printer has a finalized design and is ready to go to full production:

http://diy3dprinting.blogspot.com/2015/03/mini-metal-maker-is-ready-to-go-to.html

Newton 3d DIY metal clay 3d printer




Limited information is available on this printer, except few video showing only printing and limited photos of print results. It uses metal clay as printing material and that type of material requires high temperature kiln for finishing.
It also aims specialist makers such as jewellers, product, homeware and fashion designers.

Newton 3d homepage:

http://newton3d.com/

They have a subcategory on My Mini Factory site with some objects you could make on Newton:

http://www.myminifactory.com/search/category/96/Newton-3D-Metal-Printing































Here is a metal clay printer with similar features, the Mini Metal Maker:

http://diy3dprinting.blogspot.com/2014/02/mini-metal-maker-diy-metal-clay-3d.html

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


















Experiments in 3d printing with silver solder by Bam

User Bam from Lulzbot forums experiments with 3d printing metal solder. He had some success but there are obstacles in the road. This could be interesting for electric circuits 3d printing.


He notes:
Early experiments with metal printing with a Budaschnozzle 1.1 are looking good. Repeat: early experiments (Tin 95.8%, Copper 4%, Silver 0.2%, McMaster 76805a61). If you can wait a few days before trying this out, I'll let you know if it destroys the nozzle. Fun fact: silver solder will stick to painters tape.
The flow cuts out after about 15mm of 3mm feed, we might be able to extrude continuously with a larger thermal mass around the nozzle (metalschnozzle?). Alternately we could print in short bursts through some sort of g-code trickery.

His plans for the future:
  • Faster extrusion at higher nozzle temps (going to give an all metal noz a shot)
  • Printing through a glass nozzle (I've got some lab grade glass eyedroppers on order that I'll try to hack into a hotend
  • Smaller diameter filament (should cut down on the heat soaking up through the filament)







http://forum.lulzbot.com/viewtopic.php?f=29&t=380&p=1992&hilit=bam#p1992

Chipfuzer DIY 3D metal printer by Mark Miller

Chipfuzer is a project by Mark Miller which uses metal chips / shavings / chips left after sawing metal plates and welds them together. It is basically computer controlled welder that welds 3d metal objects.

Video of the early Chipfuzer version



Chipfuzer DIY metal 3d printer

Chipfuzer print chamber

Some metal particles 3d objects printed / welded by Chipfuzer


Chipfuzer DIY metal 3d printer with electronics

More advanced DIY 3d printed metal part

Printed metal part mounted on functional part (linear actuator probably)











































































































Mark writes this about his machine:

"The printed parts are metal. I am using high voltage and electrostatic depositing.....sorta.. in a bizarre looking chamber with a rotating building pedestal, a hopper with a tube of fine metal particles(from my bandsaw), and did I mention high voltage? Lots of snapping, popping, and sort of a welding sound....but its fast. The shapes are pretty simplistic to start off, and as can be seen grainy finish, but much to my surprise stable enough to sand and machine a bit.
In the very early stages, will report more later....."

I asked him about this machine and he wrote me this:

Right now still a work in progress but getting better every day. I am now designing safety features in it as it uses rather high voltage. I have been making electrode redesigns, HV power supply filtering(to eliminate RFI) and hoping to scrounge up some more electronics to make a second machine. The last few days I have been designing a 3D scanner that will scan parts to be made on/for this machine.
When the machine is ready for primetime, I have every intention of open sourcing it.

More detailed technical information about it are unavailable at the moment.
I'll keep my eye on this cool project and I hope it grows. Metal 3d printing would be great step forward for DIY community.

Mark Miller Google+ profile with more information on Chipfuzer:

https://plus.google.com/u/0/117449506018831131711


Update (5.2.2014):

Here is a new MIG welder based open source metal 3d printer:

http://diy3dprinting.blogspot.com/2014/02/open-source-diy-metal-3d-printer-made.html

Here is the Chipfuzer V 2.0 - smaller and better:

http://diy3dprinting.blogspot.com/2014/02/chipfuzer-v-20-of-arc-welder-based-diy.html




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