Showing posts with label filament extruder. Show all posts
Showing posts with label filament extruder. Show all posts

Aleph Objects and IC3D Develop First Open Source Filament

Aleph Objects, makers of the LulzBot brand of desktop 3D printers and parts announced a partnership with IC3D to develop the first open source filament. The main goal is to democratize manufacturing.
The filament is Open Source Hardware Association (OSHW) certified.



Video of the talk at the 2017 Midwest RepRap festival:



GitHub repository with filament specifications and other materials:

https://github.com/IC3DPrinters/filament-extrusion/tree/master/Open%20Source%20Filament


Lulzbot is also selling the filament at 35USD per 1kg spool:

https://www.lulzbot.com/store/filament/IC3D-ABS

Source news release:

https://www.lulzbot.com/filament-freedom

Precious Plastic DIY Plastic Recycling Machinery

Dave Hakkens developed a great set of open sourced DIY machines for recycling plastic. There are several machines including a 3d printing filament extruder. Every device is well documented with manuals, open sourced and uses simple and easy to find components. There is a shredder, extruder, injection molding machine and compression forming chamber.

here is the promotional video:




You can learn something about many types of plastics, which are everywhere! Like difference between thermoplastics and thermoset plastics:




3D printing filament extruder demo:




Here is a video explaining how you build it:



Here are some things you can make with recycled plastic, ranging from lamp shades to building blocs:



Project homepage where you can learn how to build each machine and about the plastics as a material:

http://preciousplastic.com/en/

You can find all the documentation on:

https://github.com/hakkens

Now, recycling plastics is great idea and useful skill to have, but will it decrease the usage of plastics in general? I do not have the data, but i have strong doubts that it will not. There is a something called Jevons paradox that notes that the more efficiently we use a resource, the rate of a consumption of that resource will increase.  Think about it ....



BTW: Dave is a very cool guy, do check his youtube channel: https://youtube.com/user/hakopdetak

Here is his pro-tip video on how to get organized as a DIY / Hacker / Maker guy with industrial plastic crates:

Multistruder DIY Filament Extruder

Multistruder is a new Arduino controlled filament extruder that can enable you to make your filament directly from the pellets.

KS video:




Project description from the project page:

How is the Multistruder Different From Other Filament Extruders:
  • The Multistruder is designed to do be a multi purpose plastic extrusion tool. In other words it is designed to do more than just make filament. This is done by swapping out modular parts on the extruder (ex: Injection Molder (hint hint)). More details coming soon.
  • Open source and easily modable Arduino microcontroller "brain" making it very user friendly to control and configure and the ability to add various expansion modules to give you better extrusion performance.
  • Only need to interact with the Arduino brain. Then the Arduino sends those instructions to everything else.
  • TFT Full Color Touchscreen is included standard for easy realtime feedback and complete user friendly control of your extruder (Almost like using a phone)
  • All Metal Construction making for a durable extruder allowing for a long service life and less issues in the long run while still allowing ease of modability for the user.
  • Drive Motor Control allowing for precise control of extrusion speed.
  • Expansion Module support for spoolers, diameter control, etc. Whether you make your own or you buy them. 
  • Multiple vertical mounting options.
  • The Multistruder comes 95% ready to go (as well as tested) out of the box all you have to do is install it in your work space, add plastic then your ready to extrude filament.
  • Vertical Space Saving design: estimated to take up about 15" H x 15" L 6" W
  • SOMETHING IS REQUIRED TO MEASURE DIAMETER OF FILAMENT EX. CALIPERS.

Specs Of Prototype ( Production version > Prototype version):
  • Extrusion Speed: <~3 feet per minute (extrusion speed will be tuned by controller to get filament diameter consistency).
  • 1 Kg Spool: <~ 8 Hours
  • RPM: ~10 RPM
  • Torque: ~167 kg.cm
  • 1.75mm extrusion cap (you can ask for 1.75mm or 3.00mm)
  • 110 Watt Heater + 5 Watt Controller + 24 Watt Motor = so max = ~139 Watts. True wattage is alot less than 139 around 84 as the heater band is not always on
  • ~2 Cents/hour operating cost at 15 Cents/kWh
  • Extrusion Temp: up to ~400C

Here is a Multistruder development blog:

http://www.thegreenengineers.com/index.php?/blogs/blog/1-multistruder-dev-blog/

They had a successful KS campaign:

https://www.kickstarter.com/projects/1718006136/multistruder-filament-extruder/description



How to make a DIY plastic shredding device from wood pieces and metal pipe

dmwatkins developed and published this DIY plastic shredder that you can use to recycle your failed prints or scrap plastic to make new filament as a pre-processor for a filament extruder.

It uses some wood pieces and cut metal pipe and it is hand operated. Rough and basic but gets the job done.



Detailed build guide:

http://www.instructables.com/id/Plastic-shredder-for-making-3D-printer-filament/

Felfil Open Source Filament Extruder




Felfil is a new open source filament extruder from Italy. It will enable you to recreate it in your home workshop and produce filament from pellets.

Felfil homepage:

http://felfil.com/?lang=en

Extruder details and downloads:

http://felfil.com/felfil/




















Improved version of FelFil, the FelFil Evo is on Kickstarter:

https://www.kickstarter.com/projects/948513712/felfil-evo-a-filament-extruder-for-3d-printers-mad


Here is video of it:





FilaFab filament extrusion system and filament winder




Here is a new filament extruder and winder system named FilaFab that will enable you to make your own filament from pellets. You can also recycle old prints and other plastics, experiment with colors and compounds, and extrude materials like ABS, PLA, EVA, HDPE, and nylon.

FilaFab Kickstarter campaign with more information:

https://www.kickstarter.com/projects/1574214560/filafab-first-professional-filament-extruder-and-w

FilaFab company page: http://www.filafab.co.uk/








ExtrusionBot EB2 modular and fast filament extruder with cruncher and spooling modules

ExtrusionBot has new flagship filament extruder model: the EB2. It features high extrusion speeds at 6,5 feet per minute and modules that can be attached to it like cruncher that will shred 3d printed objects for recycling into new filament and spool winder.

Technical specifications:
  • automated touchscreen user interface
  • expanded materials (Nylon, HDPE, LDPE, HIPS, PET, plus ABS and PLA)
  • filament cooling mechanism
  • universal power adapter
  • embedded pellet hopper
  • 2 USB ports for smart module attachment
  • Price: 899 USD


Spooler module will ensure that the extruded filament is properly coiled up


Cruncher module will crunch your failed or unwanted 3d printed objects and make new filament from them


















ExtrusionBot EB2 homepage:

http://www.extrusionbot.com/product/the-eb2/


Here is a video of Cruncher module destroying plastic clamshell packaging.

I HATE THOSE THINGS!

Finally something useful you can make with them.



If this is too expensive for you and you have some mAd Sk1Lz you can build your own filament factory:

http://diy3dprinting.blogspot.com/2014/07/filament-factory-low-cost-diy-filament.html


Producing 3d printing filament on commercial scale

Here is a Make: interview with Josh Smith, owner of Makergeeks.com about how 3d printing filament is produced on more industrial level for mass markets.
The most interesting thing about it is explanation of complexity of the technology used and need for exact temperature control in several steps.
Also the fact that the final diameter of the filament is not produced by different exit nozzle diameter but all filaments are pulled trough the same nozzle and the diameter is achieved by applying different temperature.





Source: Make

Laser diameter sensor control unit

ProtoCycler filament extruder that uses pellets and has integrated recycling grinder

ProtoCycler is new filament extruder with integrated recycling grinder that can also make filament from pellets. It should enable you to produce cheap filament from scrap objects for 0$ since it has integrated grinder or from pellets for some 5$ per one kilogram. On other important feature is integrated spooling winder mechanism. It is developed by ReDeTec from Canada.

ProtoCycler description from the IndieGogo page:
ProtoCycler is a new product that allows you to recycle waste plastic into valuable 3D printer filament - safely, quickly, and easily! It comes complete with a built in grinder, intelligent computer control, safety certification, and real time diameter feedback, so anyone can make their own filament hassle free. It also saves you a *TON* of money! Even the cheapest spools are around $30 to buy new, and they can certainly cost much more than that. ProtoCycler lets you make the same 1 kilogram spools for just $5...and if you recycle, your spools are FREE!
This means that ProtoCycler will pay for itself in just 10-20 spools - and as anyone who 3D prints knows, this doesn't take all that long. Never mind all the waste you'll divert from the trash bin. Simply put, if you 3D print, you need ProtoCycler!
ProtoCycler technical specifications:
  • Diameter tolerance: +/- 0.02mm
  • Extrusion speed: Up to 10 ft/minute
  • Electrical usage: 60 W Average
  • Dimensions: 14" x 12" x 10"
  • Grinder input: 5" x 5"
  • Hopper Capacity: Expandable
  • Max Temp: All metal hot end for 400+ C
  • Price: 799 USD range
ProtoCyler features:
  • First consumer extruder with UL certification
  • First extruder with grinder for built in recycling
  • First extruder with diameter feedback and computer control
  • Distributed Spooling
  • Automatic start up and shut down
  • Full Manual mode for hacking
  • Open source software and community
  • Beautiful brushed aluminium enclosure
  • Patent pending MixFlow extrusion technology


Comparison of ProtoCycler to other filament extruders, bot DIY and prosumer models  


























ProtoCycler video presentation:




Indigogo campaign:

https://www.indiegogo.com/projects/protocycler-free-sustainable-3d-printer-filament

Company page: http://www.redetec.com/



Erectorbot large volume 3d printer and Erectostruder pellet extruder














Erectorbot is new large volume DIY 3d printer developed by Leonard Dodd. Beside large volume it features exchangable heads for a CNC plasma cutter, router, and welder.

From EB1 homepage:
ErectorBot or EB1 is a large scale 3D printing full service gantry bot. Part of a series, our EB1 is the largest of the group. Just as in racing, we pushed the limits of precision and then bring this technology back down to size. So whether its our desktop model, 3ft x 2ft x 2ft or it’s one of the 3 larger models we offer.
You will enjoy TWICE the printable space (build area) in the same amount of space as you will find in the more conventional setups. This also allows us to treat the heat bed a little differently as well. No weight issues. Dynamics don’t change as your model grows. And neither should your wallet. The stationary bed design is modular and very low cost. And how about NOT HAVING to level the bed every model or run? We can choose our table to tip gap by extruder temp.

It will be priced at range of $11,500 to $35,000.

http://www.erectorbot.com/


Erectostruder is pellet 3d printing exruder that can also be mounted on EB1 that can use different types of materials and be used as a filament extruder.




  • Runs even the small Nema 17 and powerful doing so.
  • Shift-able planetary gears (high -Low)
  • Easy clean up (4 thumb screws)
  • Extreme temp range – frozen slush to 300 C
  • Resolution – the smallest standard up to 2mm
  • Customization – steam punk ~ beer still- high tech (3 themes thus far)
  • Liquid Cool compatible
  • High volume hopper options – laser vac
  • Twin element for precise control
  • Two sized augers for different sized pellets.
  • Arduino micro kit (stand alone ) filament extruder mode. (Yes doubles as a filament machine.)
  • All metal main components, ultra light, TIG welded, hand crafted by a master metal modeler and serialized.
  • Quick mount/release.
  • Multi head compatible.

http://www.erectorbot.com/?p=47



Protoprint will produce filament from garbage in partnership with Indian waste pickers cooperatives






Protoprint is a social enterprise based in India that empowers waste pickers with the technology to produce 3D printer filament from waste plastic. They set up their waste plastic processing and filament extruder near waste sites and work in partnership with waste pickers cooperatives to establish the supply chain and provide more earnings for waste pickers.

Protoprint also sells 3d printers and wants to establish community 3d printing centers. 
Very interesting story, I hope we will here from it more in the future.

www.protoprint.in





Strooder filament extruder successfully financed on Kickstarter





It looks like there are more new filament extruder projects showing up every day. Strooder from UK got successfully financed on Kickstarter. It uses usual screw feed system that moves pellets to hot end extruder.
I wonder will the business model of commercial filament extruder survive in competition with DIY machines that are very cheap and easy to make like Filament Factory and if the filament prices fall. Also there is new range of 3d printers that will be able to print from pellets directly.

Strooder tech specs:



















Strooder homepage:

http://www.strooder.com/

Strooder Kickstarter:

https://www.kickstarter.com/projects/omnidynamics/strooder-first-truly-consumer-3d-printing-filament





Filament Factory low cost DIY filament extruder with detailed construction guide




This homebuilt machine produces between 4-5 meters of filament per minute from ABS / PLA pellets. That output is equivalent of one kilogram of 1,75mm filament in one hour. When you factor in that the one kilogram of pellets can be bought as low as one dollar per kilo, you get a real desktop filament factory that will lower your operating cost, especially if you produce many printed parts. The price of the parts needed to assemble this filament extruder is in 130 -150 USD range, which is really affordable. The construction is relatively simple, electric motor powered auger moves plastic pellets and pushes them trough heated extruder where they melt into continuous filament.

It was designed, built and shared by Ian McMill. Kudos Mr. McMill.


Detailed build guide and all other information can be found at:

http://www.instructables.com/id/Build-your-own-3d-printing-filament-factory-Filame/?ALLSTEPS


Filament Factory. The design has a steampunk /  mad scientist appeal :-)

Ewe Industries filament extruder from Italy




Ewe Industries is Italian startup that presented their filament extruder. Italians are well known for their industrial design and this machine is no exception. Hopefully there will be some independent reviews soon.

Tech specs:

Operating system:
  • Hardware Arduino and shields developed by Ewe industries
  • Firmware Developed by Ewe industries
Capacity:
  • Temperature Settings: Can be set to stay constant at any temperature between 40°C to 230°C
  • Extrude Rate: 25 cm\min to 50 cm\min (9.85 inch \min to 19.7 inch\min) plastic and diameter dependent
  • Input Material ABS, PLA and colorant…other materials are in test phase
  • Spooling Speed Variable
  • Hopper capacity: 500 grams
  • Nozzle dimension: 1,75 mm – 3,00 mm (interchangeable nozzles)
Dimensions & Weight:
  • Max dimension: 17 cm x 37 cm (6.7 inch x 14.58 inch)
  • Max weight: 4 kg
Display & Joystick:
  • Display Blu LCD 16×2 Lines
  • Joystick 5 Function
Power requirements:
  • AC input 100–240V
  • DC output 12 v 20A

Construction:
  • Supporting Structure Reinforced Steel

The Ewe extruder is now available for purchase on the Ewe Industries website starting at 330€. They offer 3 different options:
  • Filament Extruder Starter Kit, 330€
  • Filament Extruder Assembled Kit, 490€
  • Filament Extruder Deluxe, 690€



































http://www.eweindustries.com/




DIY filament diameter sensor projects

Here is a collection of filament diameter (width) sensors for your 3d printer which will enable you to compensate for variations in filament and get better print quality. You can make them with some basic electronics skills.

Thomas Sanladerer designed, printed and tested this filament diameter sensor. It could be used on filament making extruders as a control sensor, or in 3d printers to get better printout results. The work on it is in progress, further accuracy improvements are needed but the current results look promising.

































Files can be found at:

https://www.youmagine.com/designs/filament-diameter-sensor

From project description:
This is a proof-of-concept filament diameter sensor, currently intended for an extruder making filament. The filament centerline is 90mm above the mounting surface.
It picks up the filament's diameter between two bearings, amplifies it via the lever by a factor of 3.6, which moves a magnet in front of the hall sensor.
The hall sensor's depth is adjustable and is locked into place via the M3 bolt. Bend the hall sensor's leads 90° to the back and place the sensor in recessed spot. Lead the wires out to the front.
The 6x2mm magnet goes into the matching hole in the lever. The second hole intended for a ballpen spring, which is not needed in most use cases.
For testing, upload the included sketch to an Arduino, connect the hall sensor to 5V, ground and hook the signal pin up to A1 on the Arduino. Connect via serial at 115200 baud, it will start spitting out two values each line, the first one is the smoothed ADC value, the second one the calculated diameter.
To calibrate, insert a test object with the maximum diameter you want to measure between the bearings and move the hall sensor carriage until the ADC value just reaches a maximum. Lock the carriage in place and use that value along with the diameter of the object as the last entry in the Arduino's lookup table. Insert two (or more, if you increased NUMTEMPS) more objects of varying sizes (for example the shafts of drill bits) and fill out the lookup table. Use the idle position without anything inserted for the zero-diameter position.
Support might be required for the files as they contain 30° overhangs. If you use Slic3r, you're better off with no support material.

Here is a different project which is more heavily developed and has extensive video tutorial: the Filament Width Sensor by flipper for Lyman extruder or stand-alone applications with a voltmeter





Width sensor project description:
The idea is that with a real-time width measurement the 3D printer could compensate the extruded flow for changes in filament width. Also if there is variation between spools of filament, there is no need to calibrate for that when slicing. The g-code is independent of the filament diameter.
For filament extruders, the measured width can be used as feedback in the extrusion process.This version includes a custom designed pc board as well as a housing. A version of Marlin is modified to use the sensor data.
The sensor outputs a voltage in milimeters (3v=3mm) that is shown on the voltmeter.
I made some changes to Marlin to read the filament diameter real-time and compensate the extrusion rate. Code uses a buffer to manage the transit delay between the sensor measurement and the nozzle.

All the files, code and instructions can be found at:

http://www.thingiverse.com/thing:454584
































To learn more about the purpose of filament diameter (thickens) sensors, read this Hackaday post:

http://hackaday.com/2016/02/05/filament-thickness-sensors-what-are-they-and-what-are-they-good-for/


There is a version of a diameter sensor based on hacked digital calipers developed by Wei-Hsiung Huang. It has several issues related to digital caliper precision and internal workings but it is a good learning project with some usefulness.
























You can find all the instructions, code and build guide at:

http://wei48221.blogspot.hr/2016/03/building-diy-filament-width-sensor.html

http://www.instructables.com/id/Building-a-DIY-Filament-Width-Sensor-Using-Digital/?ALLSTEPS

Low cost DIY filament extruder by Xabbax





























From project forum post:

Low cost filament extruder made from 10 mm ID stainless steel tube, silver soldered inside an ordinary plumber 15 mm copper tube (melt zone) Auger is a 10 mm wood drill bit with the end cut off 5-10 mm in the melt zone. 1 mm hole in a brass endstop at the end of the copper pipe. Aluminium block with a 15 mm hole to fit around the copper pipe. Fixed to the outside of the aluminium two 220 volt 200 degree PTC heaters( I tried 12 volt 230 degrees but the temperature was to high) Insulated with glass fibre cloth. The ptc heaters are available on aliexpress for $1 each)
System driven with a car windscreen motor at the low speed (I have a 2 speed motor - salvaged from scrap yard)
I use the white plastic that is in the inside of the doors of scrap refrigerators. Cut it up with a circular saw and extrude that to a filament of 1.75 mm
I use this filament in my Delta printer on a daily basis.
The trick to have a nice filament is to let the filament run over a copper pipe that is suspended in front of the extruder and let natures G force take over. I fix a weight(clothes-peg) at the end of the filament as it comes out of the hole untill it reaches the floor and then move the end of the filament to the outside of a circle approximately 1 meter away.From then on the G force will take over and produce a nice circular movement of the filament to roll it on the floor .
The slightest air movement or other external force that you apply to the extruded filament will result in a kink in the filament - no fans required.
No fancy electronics involved.
Material cost to should be less than $100
This extruder was only tested with the white refrigerator plastic ( I think it is ABS because it will desolve in acetone ) - no ABS pellets or any other plastic tested.

Source:

http://forums.reprap.org/read.php?1,205005,205005#msg-205005

http://deltaprinter.co.za/filamentextruder/index.html

DIY 3d printing filament extruder by Russ Gries

Russ presents his new home project: he made his own filament extruder. It is still work in progress but it looks good. Almost all parts are recycled from other machines.






Source:

http://www.youtube.com/user/rwg42985?feature=watch

www.RWGresearch.com





























Russ is also well known for his DIY Delta printer build:

http://diy3dprinting.blogspot.com/2013/09/extensive-roctock-delta-building.html

Filament makers

Usually if you want to print something you need to have filament to feed your 3d printer. But, what if you could recycle your failed models or even recycle waste plastic and make f3d printing filament out of it? Basically suitable junk plastic is ground up, continuously pressed and melted trough extruder similar to the one on 3d printer and after cooling you get filament ready for next print job.  Currently there are two projects that I know which are developing usable technology. They are in various stages of development and availability, let's hope that this technology goes into full implementation. 


Filabot 

From filabot.com :
Filabot is a desktop extruding system, capable of grinding various types of plastics, to make spools of plastic filament for 3D printers. Not only is it user friendly, but it is also environmentally friendly. The Filabot can process things such as: milk jugs, soda bottles, various other types of plastics, and bad prints, to make new filament for a future print. Filabot will bring the real power of sustainability to 3D printing, allowing for a one stop shop to make anything.



Lyman Filament Extruder 

From http://www.thingiverse.com/thing:30642 :
The Lyman Filament Extruder is a machine that extrudes filament from pellets for use in a 3D Printer. It can extrude 1.75mm and 3mm filament with easy nozzle exchange. The material cost is about $250.
On their thingiverse page there are plans, files and guides available.


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