Showing posts with label plastic welding. Show all posts
Showing posts with label plastic welding. Show all posts

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:

LaserStacker Makes 3D Objects by Laser Cutting and Welding

Researchers at Hasso Plattner Institute have made several 3d fabrication project with laser cutting and other methods. Here is the new one: LaserStacker where they use a laser cutter to weld together 3d objects.
They even made functional scissors.




Project description:
LaserStacker uses the laser cutter to not only cut but also to weld. Users place not one acrylic sheet, but a stack of acrylic sheets into their cutter. In a single process, LaserStacker cuts each individual layer to shape (through all layers above it), welds layers by melting material at their interface, and heals undesired cuts in higher layers. When users take out the object from the laser cutter, it is already assembled.
This is a project from the Human-Computer Interaction Lab at Hasso Plattner Institute.
More Information:
http://hpi.de/baudisch/projects/laserstacker.html
LaserStacker is a research project by:
Udayan Umapathi, http://www.udayan-u.com/Hsiang-Ting Chen, http://www.ht-timchen.com/Stefanie Mueller, http://www.stefaniemueller.orgLudwig Wall,
Anna Seufert,
Patrick Baudisch, http://www.patrickbaudisch.com


Earlier project:

http://diy3dprinting.blogspot.com/2015/05/combining-laser-cutting-and-3d-printing.html


EasyWelder tool for welding filament pieces

EasyWelder is a tool that will enable you to weld and splice filament pieces together.

It is described by manufacturer as:
3D printers use as raw material plastic filament of about 360 m long, coiled. With a coil, we can make some items. But when there remain only a few meters, it is often impossible to use it. This filament is then unusable or discarded. Considering the price, it's infuriating.
It also happens that the filament breaks during printing or on the coil.
The current size of the filament coils do not allow to print large parts. The best solution would be to link together the filaments of each coil. Thus, the size of the printable parts would be no more limited.

From these findings, I have sought to develop a plastic filament welder to:
  • Print large parts.
  • Reduce filament waste.
  • Combine different colors and / or filament materials.
  • Making life easier for 3D printers.
  • Saving money.
The EasyWelder can weld the following plastic filaments:
  • PLA
  • PVA
  • ABS
  • HIPS
  • NinjaFlex and other similar filaments
  • PEG
  • Nylon

Here is how it works:



It is priced at 69-80 euro range. You decide if it's worth it. I wander if there are any DIY solutions?

Hackaday.io page: https://hackaday.io/project/5726-easywelder-welder-for-plastic-filaments

Tool homepage:

http://www.i3dinno.com/easywelder-en-p186486.html

Something simillar was developed with FUSE clamp:

http://diy3dprinting.blogspot.com/2014/07/fuse-clamp-filament-welding-device-for.html


EasyWelder tool and clamp

How to use friction welding to repair and make 3d printed objects

Here are two video guides by youtube user Scorch on using a Dremel based DIY friction welder. Great work Scorch!

Here is a video on how to make a Buckyball from 3d printed hexagons:



... and video on how to repair 3d printed objects:




Friction welding works with both PLA and ABS.

While good people of Hackaday think this is a new 3d printing technique it is actually used for a quite some time now.

here you can see it in action making and repairing stuff:

http://diy3dprinting.blogspot.com/2014/01/how-to-friction-weld-plastic-with.html

... and here you can see a guide on how to make it work and make a small DIY plastic welder:

http://diy3dprinting.blogspot.com/2013/01/diy-friction-plastic-welder-by-fran.html

And if you want to use 3d printed plastic rivets for friction riveting things together:

http://diy3dprinting.blogspot.com/2014/01/3d-printed-rivets-for-friction-welding.html

If you want to go the ultrasonic way or DIY heat plastic welding in the "old school style":

http://diy3dprinting.blogspot.com/2012/12/diy-ultrasonic-plastic-welding.html

And here is how a friction welding seam looks like (from Scorch's video):











FUSE Clamp filament welding device for continuous and multicolored 3d printing








Fuse Camp is small filament welding device that will enable you to permanently connect two pieces of filament on-the-fly. You can attach it to your printers frame which will give you continuous filament if you run out of it or just want to add different color. Looks like a very practical gadget.

The Fuse Clamp is available in two sizes, one to weld 1,75mm filament together and the other for 3,0mm filament. It works with just about any type of spooled material, including ABS, PLA, PVA and Nylon. You can even mix multiple colours together to create multicolor prints without the need for dual extruders.

FUSE was developed by Pedro M. Librero


Fuse clamp Indiegogo campaign where you can get it for some 80 USD or 59 Euro:



3d printed rivets for friction welding plastic with Dremel tool

You can friction weld plastic together with a help of Dremel tool as described and shown here:

http://diy3dprinting.blogspot.com/2014/01/how-to-friction-weld-plastic-with.html

There are also 3d printable "rivets" that you can insert and do a sort of "blind" or Pop riveting.




























You can download files for printing them here:

http://www.thingiverse.com/thing:61510

How to friction weld plastic with filament and Dremel

Electronhacks made this video to show production process of the 3d printed fan duct. However it is also excellent demonstration of friction welding plastic with filament inserted into Dremel. The friction produced makes a strong welded bond.



Video by ElectronHacks

























Here are 3d printable rivets that you can use:

http://diy3dprinting.blogspot.com/2014/01/3d-printed-rivets-for-friction-welding.html

Here is another post about DIY ultrasonic and soldering iron plastic welding:

http://diy3dprinting.blogspot.com/2012/12/diy-ultrasonic-plastic-welding.html

Update:

here is a video with same friction welding technique with PLA plastic.



Update 2:



Luminar Products 3D Super Extruder enables you to 3d print with industrial grade plastic welding filament

Powerful large extruder project that enables you to 3d print with industrial grade plastic welding filament in several materials like: PVDF, PVC 1, PVC 2 & CPVC, Polyethylene, HMW and Polycarbonate.




From Kickstarter description:

There are generally two types of thermoplastic that are available for filament type 3D printers, ABS and PLA plastics. These filaments are available in many colors and diameter sizes of 1.75mm & 3mm (0.070 & 0.118 inch). Currently these are pretty much the only sizes that can be used in these 3D printing machines. There are other types of thermoplastic available today that are available as an extruded filament however these have larger cross-sectional diameters of 0.125, 0.156 & 0.188 (3.18mm, 3.96mm and 4.76mm). These are sold as plastic welding rod and are typically used for joining sheets of plastic together. These larger diameter filaments come in many different types of plastic that have for the most part not been used by the 3D printing community. Many types of plastic welding rod are considerably less expensive per pound than the common printer filament of ABS and PLA. So if this material could be made to work in a plastic printer you could have a greater variety of plastics for printing and lower material cost. Our solution is to create a new extruder that can be fitted to existing 3D printers to enable these printers to use all of these different diameters of filament and handle the wider range of processing temperatures for the different thermoplastics.
We have already built 3 versions of our NEMA 23 extruder so far with improvements being incorporated to each new version. We have run the extruders with various materials and are convinced we have a good product here. Our plan is to manufacture our extruders in two sizes. A large extruder driven by a NEMA 23 stepper motor and a smaller version driven by a NEMA 17 stepper motor. The larger version will be able to run all of the filament sizes from 1.75mm to 4.76mm (0.070 to 0.188 inch). The smaller version will run filament sizes 1.75mm to 3mm (0.070 to 0.118 inch). The heater block of our extruders and the nozzles are made from copper for faster and more stable temperature control. Several nozzle sizes will be available for printing various sizes and types of parts.

Our latest version of this extruder is larger than current extruders and has design improvements to allow it to take advantage of the higher temperature ranges required by the various types of thermoplastic available in the larger diameter sizes. These plastics have properties that will greatly enhance a 3D printer's usefulness by allowing it to make parts that can be used in many different environments.
The following are some of the types of common thermoplastic welding rod along with several uses and properties that would make them an attractive candidate for a 3D printed part.
PVDF Chemical restiveness of PVDF and its long lasting strength will make this a popular choice for laboratories or clean-rooms where tanks, tank furniture, fittings or cassettes could be made quickly from a computer library of components or as needed from a 3D CAD drawing for a custom application.
PVC 1, PVC 2 & CPVC with their ability to withstand UV would be great for any sort of outdoor applications or unique PVC pipe fittings. These materials also resist acids and alkalies and are commonly used in chemical processing applications.
Polypropylene makes parts with a hard surface and resists many chemicals and solvents. One interesting use for this material is its ability to make parts that have a living hinge on them, like used on the lid of a Tic-Tac candy box. It is also commonly used in clean rooms for chemical benches, tanks and enclosures.

Polyethylene available in low or high density formulations are very resistant to moisture as well as many chemicals.
HMW makes parts with a slippery surface useful for many industrial applications such as chain guides or rollers. It has excellent impact strength and good wear resistance.
Polycarbonate is synonymous with impact resistance. This transparent material has excellent impact resistance over a wide temperature range. Parts made from this plastic would have great strength and flexibility.
Our extruders, are of course, not limited to these materials and can also extrude ABS, PLA, any of the Taulman filaments, nylon, PETT, HIPS, PVA and others from 1.75mm diameter to 4.75mm diameters (0.070 to 0.188 inch). Many of these materials have previously not been available to the 3D printer community. It is our hope that this extruder will change that and be a benefit to all 3D printer owners who need parts with better strength, chemical resistance, UV resistance or other properties that these various plastics can provide.
Why are we so proud of our extruders?
  • Very compact design with a mid mounted, integrated heat sink for better cooling of both filament drive parts and stepper motor.
  • Extremely solid one piece aluminum body with mounting options on top, bottom or either side.
  • Copper heater block and nozzle for faster, more stable temperature control.
  • Plans for making two sizes of extruder, a NEMA 17 stepper motor size for smaller 3D printing machines or the larger, more powerful NEMA 23 stepper motor extruder for larger, faster moving 3D printers.
  • Precision quality, our extruders feature a spring loaded dual wheel filament drive mechanism for positive filament control. The drive wheels are made from steel and are hobbed for traction.
  • Our NEMA 23 extruders will be able to accommodate 5 filament sizes (1.75mm, 3mm, 1/8, 5/32 and 3/16 inch diameter filaments) and multiple plastic options with nozzle options for various materials and extrude diameters.

http://www.luminarproducts.com/3d-super-extruder-press-release.html

http://www.kickstarter.com/projects/172237528/improved-3d-printer-extruder-allows-more-plastic-o



Hot end made from copper 

DIY ultrasonic plastic welding

Ultrasonic welding uses high frequency sound waves to weld the plastics together. Here is a video demonstration of it in DIY system.



Site with more details form this video is down.
Here is more industrial ultrasonic plastic welder:



I don't know how applicable those methods are for 3d printed models. I know some people "weld" ABS with acetone (toxic) with varying results. It is interesting information and good to know skills.

If you want to weld broken plastic with soldering iron and you are aware of some risks and limitations here is a detailed guide:

http://www.instructables.com/id/Welding-Plastic-W-Soldering-Iron/?ALLSTEPS

Update (21.1.2014):

here is a new post about plastic friction welding with 3d printing filament inserted into Dremel:

http://diy3dprinting.blogspot.com/2014/01/how-to-friction-weld-plastic-with.html

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