How to convert your 3d printer into a CNC mill

Thomas shows us how he converted his MendelMax 3 into a desktop CNC mill. It can even mill aluminum.





Here is a link to ESTLCam software Thomas mentioned in the video:

http://estlcam.de/

Project page:

http://toms3d.org/2017/01/12/__trashed-2/

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DIY Ultimaker Tool and Extruder Changer Mechanism

Ultimaker forum user by the name of FoehnSturm presented his approach to toolchanger mechanism on the original Ultimaker machine.

It uses a custom modular direct drive extruders with hot end placed in holders mounted on printer's frame. This extruder is powered by NEMA 8 motor and has a   hotend like Merlin, Prometheus, E3D or similar. In the future it will use other tools also.
This system can hack your Ultimaker in true multitool hybrid digital fabricator.

Do keep in mind that this project is still in the development but it looks very interesting. It could be also adapted to other 3d printers. My opinion was always that the multitool machines are the future.


Here is the first prototype:




... more developed version with higher accuracy and repeatability:




Here is the mechanism working well with dual extruders doing two color printing:




Here is the high speed tool change in action:




The mechanism can have magnetic connectors and supports different tools like polishing head:



You can see the entire thread on the UM forum with much more information and insight in the development process:

https://ultimaker.com/en/community/10657-a-different-multi-extrusion-approach-um-tool-printhead-changer?page=1


You can see some of the files on Youmagine. Here is the one for the modular Ultimaker printhead that uses a direct extruder:

https://www.youmagine.com/designs/modular-printhead-nema8-worm-gear

... here are some of the files for the magnetic exchangers:

https://www.youmagine.com/designs/um-magnetic-printhead-changer

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Iteration and Repair of Existing 3d Printed Objects Without Re-printing

I have seen the future! Changing already 3d printed objects without the need to 3d print them again! Group of researchers developed this method that uses multifinctional 3d printer with laser 3d scanner and CNC milling head to make changes to the already 3d printed object to add or subtract from the previous design.

You can also repair failed prints and make changes on the fly. The developers call this system "Patching". It saves a lot of time and material. Imagine spending few minutes repairing object that would take hours to reprint!

Seeing it in action is very impressive:




Hopefully this technique will find wider application and adoption on mainstream machines and design/control software.


Project description:

Personal fabrication is currently a one-way process: Once an object has been fabricated with a 3D printer, it cannot be changed anymore; any change requires printing a new version from scratch. In this paper, we propose a different approach: instead of re-printing the entire object from scratch, we suggest patching the existing object and replacing only the unsatisfactory parts. This saves material and reduces waste, making a first step towards more sustainable 3D printing.

This project is a collaboration between Hasso Plattner Institute and Cornell University.

More Information: 

https://hpi.de/baudisch/projects/patching-physical-objects.html

The machine has several additional axis of movement with laser 3d scanner and CN mill head

Patching Physical Objects is a research project by:

Alexander Teibrich, http://www.teibrich.de

Stefanie Mueller, http://www.stefaniemueller.org

François Guimbretière, http://www.cs.cornell.edu/~francois/

Robert Kovacs, http://robertkovax.com/

Patrick Baudisch, http://www.patrickbaudisch.com

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ZMorph 2.0S 12 Toolhead 3D Printer

ZMorph is a machine that has 12 interchangeable toolheads.

Technical specifications:

• CONSTRUCTION alluminium 6 and 3 mm (precise and very rigid), other parts made of 3mm clear policarbonate and ABS
• WORKING AREA 250 x 235 x 165 mm . Maximum possible work area 300 x 235 x 165 mm (with removed/open covers)
• MATERIAL ABS, PLA, PVA, nylon (Taulman or other source), Stick filament, policarbonate, BandLay, LayBrick, LayWood, rubber, ceramics, cake and chocolate, metal engraving, wood engraving and milling , paper cutting.
• NOZZLE TYPE interchangeable hot-ends : 0.3mm, 0.4mm
• MATERIAL FILAMENT DIAMETER SUPPORTED 3 mm and 1.75 mm, depending on the extruder
• MAX. TRAVEL SPEED (TESTED) 500 mm/s
• RECOMEMMENDED PRINT SPEED WITH ABS 0.3mm LAYER 60 – 150mm/s depending on the quality required. Faster speeds possible with lower layer height. PLA can be printed faster too
• MAX ACCELERATION 3000 mm/s^2
• AXIS PRECISION 14 microns for X and Y axis, 0.625 microns for Z axis
• RECOMMENDED MINIMUM LAYER HEIGHT 0.1 for ABS and 0.025 for PLA.
• HEATED BUILD PLATFORM hardened glass 5mm, silicone heater 140W, temperatures up to 145 degrees.
• INTERCHANGEABLE TOOLHEADS plastic 3mm, plastic 1.75, plastic dual head extruder, ceramics, food (chocolate or paste etc.), dremel mount for 2D and 3D CNC milling, touch probe (buildplate calibration and 3d touch-scanning), LASER toolhead for cutting and engraving, experimental 5-axis toolhead. More toolheads are planned to be released in upcoming months.
• ELECTRONICS Sunbeam 2.0, with ARM LPC1769 processor, equipped with 5 stepper motor drivers – 3 for XYZ axis, 2 more for double-material extruder. Run by Smoothieware (http://smoothieware.org/).Internal disk drive accessible via USB.
• NAVIGATION LCD display panel with custom menu and graphics
• COMMUNICATION USB and LAN (can use WIFI to communicate). Stand alone printing supported via Panel + internal SD card.
• EXTERNAL DIMENSIONS 530x555x480 mm
• WEIGHT 20kg with packaging (basic version)

Here is ZMorph PCB milling:




... and here it is laser etching:




Here is the short overview of tool changing procedure:



ZMorph homepage:

http://zmorph3d.com/3d-printers/

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Limitless 3d printer and CNC mill hybrid

Project description from the maker:

Limitless is a revolutionary new automated multi tool. With Limitless, projects and ideas can be brought to life using one of many methods. Inventors and engineers can bring projects to life using the milling machine, 3d printer and other tools we plan to add such as a laser cutter. Limitless is a dynamic platform which is always changing to suit the needs of its users.

Unlike all other personal platforms, Limitless uses a robust controller similar to the ones found in industrial machines. We do not use all-in-one controllers for our automation. Each one of our large stepper motors has its own motor driver with separate power supply. We also provide the largest work space out of any other brand! With a granty clearance of 14 inches and a table size of 23.5 x 33 inches, we are the largest most versatile CNC combo tool one can buy!

With Limitless real prototypes can be produced! Since we have such a large work area, projects often do not need to be scaled down. Buy upgrading to our 6 axis controller a lathe option can be added as well, adding even more versatility to the platform. Also, all of our tools (Spindle, 3d printer, and, potentially a laser) are always installed on the “Z” axis, so there is no need to swap out tool heads. You just choose the profile you plan on using and you are good to go!

Company and product page: http://advancetecheng.com/index-Automaiton.html

KS campaign:

https://www.kickstarter.com/projects/1866188127/limitless-0

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Emerging synergy of lasers and 3d printers with real-time scanning and cutting

What is cooler then lasers? Well, lasers and 3d printers combined! duh! At some time at past I have argued on some forums that lasers will become integral parts of 3d printers and I was met with lot of opposition. There have been some attempts to integrate laser based 3d scanners into 3d printers even in commercial products but it is far from wide acceptance.
Yet, adding a laser with sensing electronics can give you so much more then just cheap 3d scanning.

Here is a video by Claudio Di Leo, MIT student, who attached a Infiniter VLM-650-27 line laser to a Solidoodle which uses a 2MP web camera to scan printbed enabling it to 3d print on place object. The entire upgrade costs some 50 USD but increases the ability of the machine.




Now, what would happen if you turn up the power on the laser?

There are several simple DIY laser cutter projects based on replacing the extruder but what if a laser cutter would be a separate tool moving independently?

Here is a video demonstration of laser cutting 3d printed PLA object. As you can see it can be done easily.




Here is a project with detailed guide and software on how to make springs with a laser cutter from different materials but also features PLA 3d printed tube:



Here are detailed instructions for spring laser cutter:

http://www.instructables.com/id/Laser-Cut-Helical-Springs/?ALLSTEPS

So, what could we achieve if we integrate active lasers into 3d printers:

1. 3d scanning
2. real-time scanning of print volume for continuous 3d print calibration, sensing failure and continuation of aborted prints
3. 3d printing on objects attached to a print surface
4. laser cutting printed objects giving new dimensions to 3d printed objects
5. "standard" laser cutting of sheet materials, engraving and PCB processing

This could be the next big thing :-)

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TwinTeeth home manufacturing PCB factory mulitool with 3d printer

There are more and more home manufacturing tools and TwinTeeth is one of the more developed I saw.
It is a multitool reversed Delta machine mainly orientated towards PCB manufacturing but it can serve as 3d printer also. It is fully open sourced with plans so you can easily build it yourself or customize it to your needs. True ability for distributed manufacturing.

It has following functions and exchangeable tool options:

• UV Laser photoengraving on sensitive film or pre-sensitized boards using an ultraviolet laser.
• Drilling vias and holes using any mini-rotary tool like Dremel® or Proxxon®.
• Dispensing solder paste with precision on SMD PCB pads.
• Plotting circuits with a permanent pen-maker
• 3D printing knobs, casings, front-panels, even print circuits with conductive filament, or make circuits supports.
• Milling/Carving soft materials or etching PCB copper with a v-bit (if you prefer this etching method).

TwinTeet core inverse Delta and replaceable toolheads in front of it

Here is a video of it in action:



TwinTeeth technical specifications from the project page:

• Working area (X,Y,Z): 70x80x60mm reduced considerably to an “Arduino™ shield-size” because it's preferred to do something small but precise. Users rarely create big circuit boards and reducing the working area has some benefits: the robot is cheaper, more precise, more robust, smaller and more manageable. However, it’s scalable, so you can make it bigger if you want.
• Motion: TwinTeeth is powered by three Nema 17 motors, lead-screws and anti-backlash nuts.
• Speed: it can go as fast as 1200-1500mm/min.
• Code: it supports G-Code, postscript and BMP files. Eagle CadSoft can export to postscript format very easily. Support BMP files means than in addition to PCBs it can also print and etch photos on copper, alu or bronze.
• Laser: using the same PHR-803T optical pickup than DiyouPCB with a wavelength of 405nm.
• Rastering: the robot draws the PCB circuits in rastering mode in a similar way any paper printer does: moving the laser (or the bed in our case) from one side of the printer to the other.
• Resolution: In rastering mode it's printing at 600DPI resolution. The laser beam spot is approx. 0.04 wide when is focused. Incredibly thin! Theorically mechanical precision is 0.94um.
• Auto bed-levelling – it keeps the bed flat with a tolerance of less than 0.01mm while the robot is moving. It’s very important to improve printing quality and provide precision.
• Auto-Focus: - small focus differences on the PCB surface affect printing quality so implemented a robust focusing system which takes some points on the PCB and extrapolates the results with a bilinear equation. With that info the robot adjusts the focus automatically while printing.
• Infrared focusing: the auto-focus system uses an infrared laser to avoid film blurring. Films or presensitized boards are only sensible to ultraviolet light.
• Electronics – using the well known combination of Arduino™ Mega + RAMPS 1.4 + A4988 Motor Drivers. Improved the Pickup Driver Circuit developed for DiyouPCB and now it includes new features.
• Precision fixture bed – it is very important to keep the PCB fixed to the bed while the robot is moving. Also, when printing two-sided PCBs you have to be sure that both sides are correctly aligned. TwinTeeth includes a precision aluminium fixture bed and dowel pins which allow correct fixing and positioning of the PCBs. A stencil is also included which helps to drill the PCB’s 4-positions holes.
• Camera – included a small USB camera because it is difficult to see tiny details on high-density PCBs. The camera is also useful to set the home position which is very important to obtain accuracy.
• 3D Printing:  FFF (Fused Filament Fabrication) with 1.75mm PLA/ABS and a 0.35mm extrusion nozzle. Printing quality is similar to any 3D printer you can find in the market.

TwinTeeth software:

• TwinTeeth Firmware: deeply modified Marlin firmware to support multiple tools, manage and control the laser, implement the auto-focus system, print in rastering mode, improve the buffering, and much more.
• TwinTeeth Management Console – TwinTeeth comes with a new easy-to-use management console which includes functionality specially designed for the multi-tool environment. Included functions to calibrate the printer, move the axis (jogging), and adjust the parameters of each tool. This software communicates with the robot through an USB 2.0 port.
• TwinTeeth Eagle ULPs – developed some ULPs (Eagles’s user language programs) to generate the drilling and paste dispensing g-code files. You can also use the files generated by other ULPs like PCBCode.
• Eagle Cadsoft – It is a popular electronic CAD software company. They provide a freeware version for non-commercial use. It easily generates the postscript, drilling and solder paste dispensing files which TwinTeeth uses to make the circuits.
• 3D Slicing software– for 3D printing you can use any slicer software like Slic3R or Cura.

TwinTeeth homepage:

http://www.diyouware.com/front

Since it is an open source project you can get all the files to make it here and start your own home PCB factory:

http://www.diyouware.com/twth_getit

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Fabrisonic SonicLayer 7200 industrial ultrasonic metal printer with integrated CNC tools

Fabrisonic SonicLayer 7200 is industrial ultrasonic metal printer with integrated CNC machining tools.
It is a BIG machine that 3d prints with aluminum tape layers which are fused together with ultrasound and then machined with CNC tools into final shape. It can produce intricate internal structures and make metal products on industrial scale.

Fabrisonic SonicLayer 7200 3d printing anc CNC machining center. Source: Fabrisonic

SonicLayer 7200 Production scale automated UAM system technical specifications:

• Integrated 3-Axis CNC Machining
• Automated Tape Feeding System
• 5000-lb load
• 9-kW power
• 72 x 72 x 36 in. Roll and Pitch Capability

Here is a video showing the machine in action:




Price is unknown.

Homepage: http://fabrisonic.com/soniclayer-7200/


Here are some previous smaller Fabrisonic machines and technology overview:

http://diy3dprinting.blogspot.com/2013/07/ultrasonic-metal-3d-printing.html

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FLUX multitool Delta 3d printer

Flux is a new delta 3d printer that has easily exchangeable tool heads and integrated 3d scanner. Currently available tool heads are 3d printing head and laser engraver head with several modules under development like: a dual extruder, a ceramics extruder, and a pastry extruder.

It is on Kickstarter now

https://www.kickstarter.com/projects/2117384013/flux-all-in-one-3d-printer-unlimited-elegant-simpl

Currently, 38 days before campaign end, it has $348,923 pledged of $100,000 goal.

Flux certainly has minimal and cool design:

Comparison chart of Flux with devices it replaces:

Flux technical specifications:

Flux company page: http://flux3dp.com/

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R & B rapid production UG hybrid 3D printer, cnc mill and 3D scanner from Germany

This new hybrid is developed and sold by "R & B rapid production UG". The German start up spun off from bbw college that has been in 3D printing business for some time.

This machine is combination of 3D printer, cnc mill and 3d scanner in one device. It is marketed as "universal machine". The toolheads can be exchanged very quickly in two minutes. 3d printing volume is 775 x 420 x 140 mm.

Full kit with all the toolheads is in higher price range of some 4000 euro, but it is more aimed at small and medium companies or high end prosumers.

http://www.rapidproduction.org/produkte.html

Update:

the company released professional grade MetalBro300 3d printer:

http://diy3dprinting.blogspot.com/2014/08/metalbro300-3d-printer-from-germany-is.html

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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

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FLX.ARM.S16 multitool low cost SCARA robot that can 3d print

FLX.ARM.S16 is industrial grade multitool SCARA motion robot that can 3d print, cnc mill, pick - place, dispense and probe.
This machine is industrial or laboratory grade tool priced at some 2000 USD which is in range of current DIY 3d printers. Similar tools at that market segment sell in 10-40 000 USD range. One can conclude that the quality is increasing, prices ar decreasing and more high-end equipment makers are going down into "prosumer" segment. This is also a part of digital fabrication and distributed manufacturing  trend where in near future you could see small robotic manufacturing cells in garages and micro companies.
It is made by Flux Integration LLC from Biddeford, Maine, USA.

Technical specifications:

• Motion Control and Simulation: FLX.IDE
• Motion Control Hardware Interface: FLX.CTL
• Connectivity: Ethernet
• Power: 100-120 VAC - 6 A 50/60 Hz or 200-240 VAC - 3 A 50/60 Hz
• Motors: Hybrid Stepper
• Reach: 16" [406.40 mm]
• Shoulder Joint Range: +/- 180 degrees
• Elbow Joint Range: +/- 155 degrees
• Angular Speed: 360 degrees/s (1)
• Linear Speed: ~ 3 ft/s [1 m/s] (1)
• Repeatability: 0.001" [0.025 mm] (1)
• Payload: 10 lbs [4.50 kg]
• Material: Aluminum - Stainless Steel - UMHW - ABS
• Weight: 15 lbs [6.80 kg]
• Environmental IP50 Rating

http://www.fluxintegration.com/pages/flx-arm#specs

FLX.ARM.S16 robot

FLX.ARM.S16 replaceable tool heads

Update:

Flux Integration has just successfully crowd-funded the low-cost version: the FLX.ARM.S16.Z8. They raised $82,905 out of $50,000 goal. I'm not sure what are the differences between models if any exist.

https://www.kickstarter.com/projects/535786699/flxarm-low-cost-precision-robotic-arm




Here are the technical specifications:

Here is the work area compared to other commercially available 3d printers:

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ZeGo delta robot with multiple tool heads

ZeGo is multifunctional delta configuration robot with multiple tool heads. It is much more then just a 3d printer. All tools can be easily replaced via magnetic joint attachments. This delta and other hybrid multitool machines are step closer towards desktop production cell. It would be interesting feature if several machines of this type could be linked and connected with some sort of transport platform. Small robotic factory on a table ...

ZeGo can use following tools:

• Plotter – An automatic drawing device used on paper or LCD sketchpads.
• 3D Printer Extruder – Prints using a fused filament fabrication (FFF) technique, and PLA plastic filament heated at 185 degrees C.
• Wood Burner – Hot end device for burning designs into various materials
• Pick&Place – Entry level pick/place machine with forth access availability
• Engraver/PCB Mill – for engraving PCB prototypes.

Company homepage:

http://zegorobotics.com/

Here is the Indiegogo campaign preview:

https://www.indiegogo.com/project/preview/7a5bfc63#home

It will be on Indigogo very soon.

ZeGo delta robot

Plotter 

Wood burner

Engraver / PCB mill

Pick and place attachment 

3d printing extruder

Things printed on ZeGo

Similar machines are:

http://diy3dprinting.blogspot.com/2014/01/mtm-multifab-multitool-desktop.html

http://diy3dprinting.blogspot.com/2013/09/zmorph-personal-fabricator-3d-printer.html

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QU-BD RPM Rapid Prototyping Mill 3d printer and powerful mill hybrid

RPM is machine in beta, hybrid dual extruder 3d printer / mill with ball screw movement, high power motors and strong mill head. Construction looks very sturdy and high quality.

• it should become open source printer
• Frame Material: CNC Machined Billet Aluminum, Anodized 
• Frame Hardware: Fully Countersunk Stainless Socket Cap Screws (Metric)
• Bed Material: 3/8" Thick Basalt (a volcanic glass) | Ground Flat | Will Not Sag Or Warp When Heated
• Heated Bed: Yes, Silicone Rubber | Fast, Even Heating
• Maximum Size 3D Printable Object (with single extruder installed)
• Approximately X-Axis 12.61" Y-Axis 13.11" Z-Axis 10.84" = 1792 cubic inches
• Minimum Layer Height .1mm or Lower
• Maximum Millable Object Size (based on Medium Duty 1HP Spindle)
• Approximately X-Axis 9.61" Y-Axis 10.11" Z-Axis 10.84"
• Printable Materials | Millable Materials
• ABS, PLA. Polycarbonate | Aluminum, Steel, Stainless Steel, Plastic, Wood etc.
• Linear Motion X | Y | Z
• X-Axis 5/8" dia Precision Ball Screw w/ 1/2" dia Precision Linear Bearings
• Y-Axis 5/8" dia Precision Ball Screw w/ 5/8" dia Precision Linear Bearings
• Z-Axis 5/8" dia Precision Ground ACME Screws (One on Each Corner)
• Motors X | Y | Z
• X-Axis NEMA 23 22kg*cm Bi-Polar Stepper Motor (Texas Instruments Based Stepper Drivers)
• Y-Axis Dual NEMA 23 22kg*cm Bi-Polar Stepper Motors (Texas Instruments Based Stepper Drivers)
• Z-Axis NEMA 23 22kg*cm Bi-Polar Stepper Motor (Texas Instruments Based Stepper Drivers)
• Maximum Mechanical Accuracy At Full Stepping / 32x Microstepping (yes 32x)
• X-Axis .0003 Inches / .00001 Inches
• Y-Axis .0003 Inches / .00001 Inches
• Z-Axis .00016 Inches / .000005 Inches
• Shipping Weight w/o Spindle 70lbs
• Electronics: Azteeg X3 (http://www.panucatt.com)
• Firmware: Marlin ... Testing Custom Firmware & Software
• Stepper Drivers: Texas Instruments Based Drivers w/ 32x Microstepping
• Power Supply: 24v (Most Likely 450w)
• Extruder: Single X-Truder w/ Dual Capable for Future Add On
• Filament: 1.75mm ABS, PLA, Laywoo, Polycarbonate, Nylon, PEEK etc.
• Max Sustained Temperature: 350c

Retail Price after Beta Program Completes

• $1999.00 for the 3D Printing Platform
• $899.00 for the Medium Duty Water Cooled 1HP Mill Package which includes a Hitachi or Baldor VFD (depending on if you want to run off 110v or 220v power) as well as a recirculating coolant system w/ radiator and fan for the spindle.
• 3HP Spindle Mill and Bosch Colt Router Package pricing TBD

Future developments:

• Automated 3D Laser Scanner Price Target <$1000.00 | Coming 2013
• Accuracy .1mm or Better
• 4th Axis w/ HUGE 115 kg*cm Stepper Motor Price Target <$1000.00 | Coming 2013
• For Turning and 4th Axis Milling of Metal, Plastic and Wood Parts
• Stereolithography 3D Printing Price Target <$1500.00 | Coming 2013
• Much Larger Build Area than Current Stereolithography Printers...we will NOT be using a proprietary resin
• Immersive Flood Cooling w/ Remotely Located Electronics Panel <$250.00 | Coming 2013

Challenges and Weak Spots

• The open-source software that is currently available for the milling side of things with the RPM is a bit lacking. We have MasterCAM at our shop and have been testing some open-source as well as commercial software packages. We are also in talks with a RepRap famous developer for a REAL software package for our machine, but as of right now the software end of MILLING IS EXPERIMENTAL! The 3D printing side of things is well sorted and obviously there are many options that work well including Marlin w/ Pronterface and Repetier.
• The BOLT ON UPGRADE that will include the remotely mountable electronics panel and immersive flood cooling setup is NOT ready, yet but may be before the end of the beta program. Milling operations may have to be run dry or with manual cooling methods at least initially in the beta program.

http://store.quintessentialuniversalbuildingdevice.com/product.php?id_product=45

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Multec MutiRap 3d printer, engraver and mill hybrid from Germany

I found this combo machine from Germany while following Mathias Dietz on Youtube, since he made a software that powers it.
It is 3d printer, engraver and mill hybrid.




It comes in two sizes, here are some technical specifications:

Multec MultiRap is driven by machine specific custom optimized GCodePrintr Android platform application made by Mathias. You can read more about it here:

http://diy3dprinting.blogspot.com/2014/01/gcodeprintr-v152-for-android-has-been.html





Product page (in German, but hey, there is Google translate):

https://www.multec.de/index.php?s=77

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DMG Mori Lasertec 65 high end hybrid metal 3d printer and 5 axis mill

When you see this machine at work, you see the future of production. The turbine housing just grows in front of you. The printed part is probably lighter and stronger since its laser is creating more carbon bonds.

Technical specifications:

• 5-axis: milling and laser texturing of plastic injection moulds on one machine in one setup
• Full fledged 5-axis milling machine from DECKEL MAHO in the rigid monoBLOCK® / duoBLOCK® Series; flexible integration of a laser head via the HSK interface
• Change over time from milling to laser operation only approx. 5 minutes
• Unlimited design possibilities for geometricallydefined surface textures in free-form surfaces
• Environmentally-friendly methods that do not require the use of chemicals
• Highest repeatability
• Fully digitised process chain
• LASERSOFT 3D texturing software package for the laser structuring of 3D surfaces: from Bitmap to the finished texture

http://hr.dmgmori.com/sites/products/en/lasertec/lasertec-65-shape

PDF brochure:

http://hr.dmgmori.com/pq/lasertec-65-shape_en/pl0uk13_lasertec-series.pdf

You can also check out this Matsuura Lumex machine with similar approach:

http://diy3dprinting.blogspot.com/2014/01/matsuura-lumex-avance-25-hybrid-metal.html

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Travel CNC and 3d printer project by Marcus Wolschon

Marcus decided to make his personal "Travel CNC" which has CNC mill, 4th axis, 3d printer, vector knife, resin casting and work table in single, mobile, quiet, clean machine.

Here is the link to his continuously updated blog post about the project progress:

http://marcuswolschon.blogspot.de/2013/07/travel-cnc3d-printervector-cutter.html

He is also developing his own 4+5 axis CAM software, so go and help him:

http://marcuswolschon.blogspot.de/2013/05/free-45-axis-cam-software.html

I hope his project will be successful and well documented!

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2BEIGH3 DIY hybrid CNC machine and 3D printer with detailed build instructions

Many people are building machines they designed from scratch. Here is combination of CNC machine and 3d printer which is well documented with complete build guide. It has some interesting features like printing with many materials.

Here is 2BEIGH3 as CNC cutter slicing trough acrylic plate:



Here is 2BEIGH3 3d printing with Nylon (btw: printing Nylon emits toxic fumes, it should be done in controlled environment):

2BEIGH3 technical specifications:

• Build volume for CNCing: 14” x 14” x 6”,  355mm x 355mm x 160mm  
• Build volume for 3d printing: 14” x 14” x 12”, 355mm x 355mm x 355mm
• Material Aluminium 3mm or 0.125" ABS and PLA Plastic Rod or Line
• Plastics 2-3mm(or 0.125") Nylon, Nylon Polymers, Nylon 6 and 6/6 - 6' Rod
• Foam 3mm or 0.125" PET (Plastic from water bottles)
• (Steel with the addition of cooling) 
• Resolution: X-Y Resolution +/- 0.005 ~ +/- 0.012, Z Resolution +/- 0.005 +/- 0.005
• Cut/Print Speed 350mm/min 24mm/s
• Cutting Foam ABS
• Tools/Tips 0.125” – 0.250” .32mm - .62mm

Software:

• Any CAD that makes “.dxf” and exports “.stl”
• MACH3
• LazyCam slic3r rev 6
• PC Win XP

This hybrid can print with various materials like ABS, PLA, different nylon polymers, acrylic and It can also print with reclaimed PET from the regular PET bottles. Here are the images of printed objects in different materials:

Here is a video of it printing in clear acrylic:





Hot end is also custom designed from simple parts:

All the details need for construction of 2BEIGH3 can be found here:

http://www.instructables.com/id/Combination-CNC-Machine-and-3D-Printer/?ALLSTEPS

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Matsuura Lumex Avance 25 hybrid metal laser sintering and high precision milling machine

This is not your Prusa Mendel. This is the Godzilla of advanced industrial 3d printers, a hybrid metal laser sintering and high precision milling machine.
It can produce highly precise medical and dental implants and high end custom aerospace industry parts. The structures can have intricate internal structure that can decrease weight, improve cooling or add advanced structural properties.
Lumex Avance can also print complex molds and casts with integrated cooling for high cycle injection molding.
Typically, milling produces debris, or chips, of removed material that vary in size. However, the LUMEX machine utilizes dry cutting, meaning no coolant is used. For this reason, the cutters are very small and the machining metal removal is a fine powder. Thus, the porosity is theoretically equal to the particle size of the powder and gets incorporated into the powder mix. Usually, no removal of milling chips is needed.

Machines like this are the future of manufacturing which is already here, just not evenly distributed.







Technical specifications:

Matsuura will go to north American market with their  hybrid 3d printer. They plan to sell ten machines in 2014 which cost 800,000 - 1,000,000 USD per piece. This reminds me of the time in early history of computing when IBM executives claimed that the world needs only 8 computers.

Matsuura press release in PDF:

http://www.matsuura.co.jp/english/pdf/2013/Matsuura_PR_LUMEX_Avance-25_Release_in_North_America.pdf

Matsura Lumex page:

http://www.matsuura.co.jp/english/contents/products/lumex.html

For even more powerful laser metal printer and 5 axis CNC mill check out this DMG Mori Lasertec 65:

http://diy3dprinting.blogspot.com/2014/02/dmg-mori-lasertec-65-high-end-hybrid.html

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MTM Multifab multitool desktop manufacturing machine

MTM Multifab is truly multifunctional desktop manufacturing machine that was very innovative and ground breaking in the field of  DIY 3d printing when it was developed. Ultimaker, very well known and powerful 3d printer,  is based on this machine.
Multifab has several replaceable tool head options:

• MACHINING SPINDLE, A high-speed (20K RPM) spindle supports light subtractive machining. The spindle can be constructed entirely from off-the-shelf compoents.
• VINYL CUTTER, A razor blade tool which allows 2D cutting of sheet material. Some applications are flexible circuit boards, stickers, silkscreen masks, and more.
• REPEATING PIPETTER, This fluid dispensing toolhead was created in collaboration with MIT's Innovations in International Health program, and has uses in automated biology research and disease diagnostics fabrication.
• PLOTTER HEAD, A pen attached to the multifab can allow easy labeling of objects, caligraphy, etc...
• 5 AXIS TRUNNION, This attachment permits 5-axis machining of components on the Multifab. Potential applications include variabl-helix screws, impellers, and 5-sided machining operations.
• PLASTIC EXTRUDER, Based on the Rep-Rap project, this extrusion head will enable additive manufacturing in plastics such as ABS.

MTM Multifab 3d printing

Here are some videos of Multifab in action writing and pipettering:





Demonstration of the MTM Multifab fitted with an auto-pipetting toolhead. The toolhead was designed with Amber Houghstow and Jose Gomez-Marquez of the MIT Innovations in International Health program, with the goal of automating production of XoutTB diagnostic assays. Perhaps it can also find a use in the DIY Bio community.
The MTM Multifab is part of the MIT Center for Bits and Atoms Machines That Make project.

Here is overview of Multifabs components, tools and development status:

http://mtm.cba.mit.edu/fabinabox/devmultifab.html

The instructions, plans and BOMs should be available for anyone who wants to build it, but all the files and documents links I tried on the site were broken. I hope it will be repaired soon, the public could benefit greatly with this machine.

Fab-in-a-Box

The Multifab is core machine of FAB in a Box framework system that should provide full digital fabrication environment that user could make at their home from simple parts. It contains:

Infrastructure. All of the key services which allow Fab-in-a-Box to be a cohesive toolset. These include the network, the box itself, power distribution, etc. It consist of the:

1. VIRTUAL MACHINE ENVIRONMENT, The flexible Fab-in-a-Box machine control and interface environment.  
2. THE NETWORK: FABNET, An RS485-based network is the nervous system of the toolset, which connects the "brain" - a laptop running control software - to the tools and sensors comprising Fab-in-a-Box. 
3. THE SUITCASE, The suitcase is the heart of the matter. It is what contains the entire fab in a box project.

Multifab. A computer-controlled multipurpose fabrication tool. Work includes integration into the box, the xyz motion stage, and multiple toolheads to perform various fabrication tasks. Multifab has many subsystems, components and parts:

1. XYZ GANTRY, The key component of the multifab tool is a high-speed and rigid xyz gantry capable of accomodating a wide range of fabrication processes.  
2. 3-AXIS MOTION CONTROL, The multifab gantry is controlled by a networked controller board capable of controlling three stepper motor drivers simultaneously.  
3. H-BRIDGE, This module is able to control the average voltage across a load, such as the spindle's DC motor, using a technique called Pulse Width Modulation (PWM).  
4. RC SERVO CONTROLLER, RC servos, typically found in radio controlled airplane models, use feedback to control the position of their output shaft. This controller can set the position of up to 8 servos, and is used in the auto-pipetter toolhead.  
5. MACHINING SPINDLE, A high-speed (20K RPM) spindle supports light subtractive machining. The spindle can be constructed entirely from off-the-shelf compoents.  
6. VINYL CUTTER, A razorblade tool which allows 2D cutting of sheet material. Some applications are flexible circuit boards, stickers, silkscreen masks, and more.  
7. REPEATING PIPETTER, This fluid dispensing toolhead was created in collaboration with MIT's Innovations in International Health program, and has uses in automated biology research and disease diagnostics fabrication.
8. PLOTTER HEAD, A pen attached to the multifab can allow easy labeling of objects, caligraphy, etc... 
9. 5 AXIS TRUNNION, This attachment permits 5-axis machining of components on the Multifab. Potential applications include variabl-helix screws, impellers, and 5-sided machining operations. 
10. 1-AXIS MOTION CONTROL, Additional axes can easily be simultaneously controlled by adding them onto the network. The disadvantage as compared to a multiple-axis controller is increased network load.
11. PLASTIC EXTRUDER, Based on the Rep-Rap project, this extrusion head will enable additive manufacturing in plastics such as ABS.
12. JOG DIAL, The multifab can be positioned by hand using a networked jog dial. This interface can also provide more complex control of parameters typically adjusted on the computer such as feed rate.

Other Fab. All other tools needed to make something. Examples are the soldering iron, hand tools, and programming interfaces.

1. SOLDERING IRON, A soldering iron with temperature adjustment over the network.
2. AUTO BINS, Parts bins which light up to indicate where a needed component is located. This could be part of a computer-assisted-stuffing project.
3. FUME EXTRACTOR, A fume extractor with a ring of LED lights around its intake.
4. IN-CIRCUIT PROGRAMMER, A network-attached microprocessor programmer.
5. NETWORK BOOTLOADER, A bootloader which fetches programs over Fabnet.

Measurement. Networked instrumentation such as a multimeter and oscilloscope. This is one area which will hopefully expand greatly on the road.

1. MULTIMETER, A multimeter which displays and records its readings on the Fab-in-a-Box laptop.
2. OSCILLOSCOPE, An oscilloscope which displays and records its readings on the Fab-in-a-Box laptop.

Autodoc. Everything related to making it possible to document a project "without thought".

1. EYE-FI CAMERA, A camera which wirelessly tranfers its time-stamped images to the Fab-in-a-Box auto-documentation software.
2. RFID READER, Keeping track of which hand tools were used, and when, is made easy with an RFID reader.

Some of the components were never developed, and most of the building related file links can not be opened. Probably all the files are somewhere on the internet, it would be terrible if they get lost forever. I REALLY hope someone publishes them as open source soon.


Here is the Fab-in-a-Box website:

http://mtm.cba.mit.edu/fabinabox/

PDF presentation:

http://mtm.cba.mit.edu/fabinabox/fabinabox.pdf

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