Showing posts with label resin. Show all posts
Showing posts with label resin. Show all posts

New Rapid Liquid Printing 3D Printing Process from MIT

Very smart people from MIT developed a novel 3d printing process called "Rapid Liquid Printing" where a material is injected into a gelatine cube medium that acts as a support. It increases the speed and you can get complex geometries.

You can see it in this video:





Process description:
In collaboration with Steelcase, we are presenting a new experimental process called Rapid Liquid Printing, a breakthrough 3D printing technology. Rapid Liquid Printing physically draws in 3D space within a gel suspension, and enables the creation of large scale, customized products made of real-world materials. Compared with other techniques we believe this is the first development to combine industrial materials with extremely fast print speeds in a precisely controlled process to yield large-scale products.
3D printing hasn’t taken off as a mainstream manufacturing process for three main reasons: 1) it’s too slow compared to conventional processes like injection molding, casting, milling, etc. 2) it’s limited by scale – although it’s good for creating small components, it’s not possible to produce large scale objects 3) the materials are typically low-quality compared to industrial materials.
Rapid Liquid Printing addresses all of these limitations: it is incredibly fast (producing structures in a matter of minutes), designed for large scale products (you can print an entire piece of furniture) and uses real-world, industrial-grade materials.

It looks interesting as a concept, but practicality is questionable. It takes a lot of gel support material, there are various foces, hard to design geometry due to the medium, the extruder "needle" effects the object geometry, materials need to be easy to separate... Still, it looks very promising for some future advanced applications and bioprinting.

MITs Self-Assembly Lab page:

http://www.selfassemblylab.net/

Detalied article on Dezeen:

https://www.dezeen.com/2017/04/28/mit-self-assembly-lab-rapid-liquid-printing-technology-produce-furniture-minutes-design/




DIY rotational casting machine made from wood and 3d printed parts

If you want to expand your home manufacturing arsenal, here is a very useful machine that will enable you to make hollow objects from various types of resin.
This machine is easy and cheap to make from 3d printed parts and 15mm MDF sheets cut on a CNC machine. It was published on Instructables by Jorge Dorantes.
It is hand cranked, but it could probably be easy modified to run with a simple electrical motor.




























All the files and instructions can be found at:

https://www.instructables.com/id/Rotomoldeadora/?ALLSTEPS


If you are not sure how this machine works, here is a demonstration video of a different rotational casting machine by TGS Props where they use two piece silicone mold and Smoothcast 65D resin to make, well ... raptor / alien  eggs!


RooBee One Open Source DLP SLA 3D Printer

Aldric Negrier developed this DLP projector based open sourced 3d printer. It looks easy to assemble and cheap to make. It all depends on how cheap can you find a suitable projector. 

Project description:
Roobee One is an SLA DLP 3D printer inspired on the Cristelia - SLA/LCD 3d printer and the Vulcanus MAX 3D printer.
It is built out of 20x20 mm aluminum profile chassis, It has an adustable print area of 80x60x200 mm up to 150x105x200mm build volume using a ACER DLP projector.
The open-source machine is called RooBee One because it is red color just like a Ruby gem.

RooBee One presentation video:



Detailed build guide can be found at:

http://www.instructables.com/id/RooBee-One-SLA-DLP-Aluminum-Frame-3D-Printer/

Thingiverse page:

http://www.thingiverse.com/thing:2001118

Cristella 3d printer (open source, daylight):

http://www.thingiverse.com/thing:1680172




ONO Smartphone Illumination DLP 3D Printer

ONO is a novel approach to 3d printing and it uses your smartphone as a light source for curing of daylight resin. It should cost just 99$.
DLP 3d printers that use visible light from an LCD panels are getting more developed and should lower the price.


Here is Adafruit Industries talking with ONO crew about their machine:




ONO homepage:

http://www.ono3d.net/

PS: I'm not sure how do they expect that millennials give up their phones for the time needed to print something...



Low Cost DIY UV Curing Chamber

kidNeutrino shared this great solution to UV curing of resin 3d printed parts. It's a low cost DIY solution that can be made for some 30 USD and consists of aluminum foil covered cardboard box and a gel nail dryer lamp.
You just put your part in, turn on the dryer UV lamp and let it cure.
























Instuctables page with step-by-step build guide:

http://www.instructables.com/id/Low-Cost-UV-Curing-Box-for-3D-Resin-Prints/?ALLSTEPS

SprintRay MoonRay High Resolution UV DLP 3D Printer

SprintRay presented their MoonRay high resolution UV DLP 3D printer. It will be priced at  3499 USD.















Key features:

  • Custom-built projector for 3D printing fine details: MoonRay’s resin requires UV light for proper curing. Other similar 3D printers use commercial projectors, which produce visible light but not pure UV light. The advantages of the custom UV LED projector in MoonRay are in the resolution and curing process. The MoonRay’s UV projector, RayOne, was custom designed with some special qualities:
  • Perfect light spectrum: The resin used for 3D printing cures under light with a 405nm wavelength. The custom-built projector hits the proper wavelength consistently across the build platform, which allows you to get real 100-micron resolution.
  • Runs cool and quiet: Utilizing a UV projector allows the MoonRay to avoid any overheating and makes it much quieter than other 3D printers.
  • Long lifespan: RayOne’s 50,000-hour lifespan means you won’t ever need to replace the bulb.
  • Revolutionary resin tank: the team designed the MoonRay’s resin tank to last, so there’s no more replacing your printer’s resin tank or changing the PDMS layer


MoonRay presentation:




Here is MoonRay on CES 2016 with more detailed presentation:




... it makes very fine objects like this 3d printed cloth:



SprintRay homepage:

http://www.global.sprintray.us/moonray




Resin based 3d printable ceramic with high-end properties





Scientists at HRL developed new resin ceramic material that can be 3d printed using stereolitography and has high strength and resistance to temperature. Amazing advances!


Project summary:
Researchers at HRL Laboratories, LLC, have achieved a new milestone in 3D printing technology by demonstrating an approach to additively manufacture ceramics that overcomes the limits of traditional ceramic processing and enables high temperature, high strength ceramic components.
HRL’s Senior Chemical Engineer Zak Eckel and Senior Chemist Dr. Chaoyin Zhou invented a resin formulation that can be 3D printed into parts of virtually any shape and size. The printed resin can then be fired, converting it into a high strength, fully dense ceramic. The resulting material can withstand ultrahigh temperatures in excess of 1700°C and exhibits strength ten times higher than similar materials.
Ceramics are much more difficult to process than polymers or metals because they cannot be cast or machined easily. Traditionally ceramic parts are consolidated from powders by sintering, which introduces porosity and limits both achievable shapes and final strength. "With our new 3D printing process we can take full advantage of the many desirable properties of this silicon oxycarbide ceramic, including high hardness, strength and temperature capability as well as resistance to abrasion and corrosion." says program manager Dr. Tobias Schaedler.
The novel process and material could be used in a wide range of applications from large components in jet engines and hypersonic vehicles to intricate parts in microelectromechanical systems and electronic device packaging.

HRL Laboratories page:

http://www.hrl.com/news/2016/0101/


The HRL team’s research paper, "Additive Manufacturing of Polymer Derived Ceramics," has been published in the January 1st issue of Science.



3d Printing with Multi-part Polyurethane

The Structur3d crew made a extensive attempts to 3d print with multi par polyurethane resin. They used custom print heads with mixed results. Mos tof the parts failed, but they are slowly moving towards success. If you want to experiment and see several techniques do check out their research.































Very detailed page with step-by-step process, extruder technology and g-code examples:


http://www.structur3d.io/blog/2015/12/3/3d-printing-with-polyurethane


Here is the video of the process:


Chimera DLP 3D Printer You Can Build for Under 60$

Here is one of the cheapest DIY 3d printers you can make, with cost at around 60 USD, and it is DLP SLA machine!
It also comes with very detailed construction guide made by the developer "matstermind".

How can the price be so low? Mostly by using used or scraped parts. You can see it in the parts list below.

Bill of materials:
  • 1x Mitsubishi XD221u 1024x768 video projector, used or second-hand $50
  • 1x computer disc drive laser deck assembly (must be one with a stepper motor), free from scrap disc drive
  • 1x Arduino UNO / Duemilanove or atmega328 based Arduino clone, $4 ebay, used or second-hand
  • 1x Easydriver v4.4, $2 from ebay
  • misc wire, solder, etc.
  • (optional) Ability to etch circuit boards (you can protoboard/breadboard it if you have to)
  • (possibly) 5v, .5A power supply. Some laser decks can be powered by the USB port by the Arduino, some may need a power supply to be plugged into the Arduino or M+ on the easydriver to make the motor move. It will depend on the power of your USB port. My deck did not need one.
  • Total=$55.5
  • (optional for frame) scrap wood for free or 2x4ft MDF board or $10 from hardware store

Looks rough and simple with wood frame. I like the style ...

Chimera is named inspired by mythological creature that is made up of three different animals since this printer is made by using the recycled/modified parts of three different categories (projector, toys, and old computer stuff), hence the name.

Video of Chimera working its DLP resin hardening magic:





Print quality looks good:




Chimera has a very detailed construction guide at:

http://www.instructables.com/id/Chimera-60-DLP-resin-3d-printer/


SLA 3D Printed Working DIY RC Micro Drone "Air-Form 1"

Thingiverse user "niklasm" designed and 3d printed a fully working micro RC drone from tough resin on a Form 1.
























Technical specifications:
  • battery: 150mAh
  • thrust: 54g
  • weight: 60g
  • wingspan: 58cm
  • dihedral: 15deg
  • flight time: 11min
Non-Printed Parts:
  • specktrum ar6410
  • 150mAh battery
  • laTrax motor
  • laTrax bearings
  • laTrax gear/propshaft
  • laTrax prop
  • 3/32in X 7/32in X 3ft rectangular carbon rod
  • 3/16in carbon tube
  • 7/64 carbon rod
  • 3ft X 3in X 3/32 balsa board
  • 1/32in music wire
  • superglue

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

http://www.thingiverse.com/thing:1051655

Form 2 is a New FormLabs Flagship SLA

Formlabs just released Form 2, the new desktop SLA machine. It is a 40% larger 3d printer than its predecessor. You can find all the specs on their page, it wil be priced at 3499 USD range.

Great step forward!

Only thing that drew my attention is their new "Automated Resin Systems". It looks like proprietary cartridge and it has an ID chip. I'm not a big fan of that setup but they claim you will be still able to use and experiment with third party resins in "Open Mode". We will see how this situation develops. If they close their machine so it can only use Fromlabs resin, someone will probably hack it making chip protection obsolete.


There are still no third party reviews or tests.

Update: here is a review by Make:

http://makezine.com/2015/09/22/review-formlabs-brand-new-3d-printer-the-form-2/


Introduction video:




Here is the unboxing video:




Detailed Form 2 launch presentation:



Form 2 homepage:

http://formlabs.com/products/3d-printers/form-2/

Update:

here is a detailed review by Tested where you can see potential problems and print failures:





Tough Resin from FormLabs

New advances in resin materials with FormLabs Tough resin. SLA is surely being area of slow but steady developments and could take over FDM one day in desktop machines.

Suitable for:
  • High-impact/high-stress components
  • Snap-fit functions and living hinges
  • Machining
  • Cyclic loading
Not suitable for:
  • Very fine features or thin walls
  • Rigid or stiff prints
  • High-temperature applications
  • Constant loading



Tough resin homepage:

http://formlabs.com/products/materials/tough/




Autodesk releases files for Ember 3d printer

Autodesk made all the mechanical files for their Ember SLA 3D printer publicly available making it open source. It comes shortly after they have open sourced the PR48 resin for it. The Ember itself proved to be very hackable.

Why did they do it? Maybe to gain market for their Spark platform? As a sort of move against competition? Who knows ...  How will other companies like FormLabs react? That will be interesting! I see that SLA is the new field of growth and competition and we can certainly hope for much more new machines and materials coming soon.







Here is what Autodesk team writes about this move:
With these design files, you can conceivably make your own Ember. However, many of Ember's parts are injection molded, and while it is possible to 3D print these parts (many of Ember's first prototypes were largely 3D printed -- there's a certain beauty in a 3D-printed 3D printer), it's probably more work and ultimately more expensive than buying an Ember. The same is true of the projector -- having a Fusion model of the projector won't help you make your own, but that's not the point.
Our thought is not that you would duplicate Ember, but extend it. The design files allow you to make your own modifications and enhancements. For example, we'd love to see Ember used as a research platform to explore the next-generation of stereolithography.
All the mechanical files can be found at:

http://spark.autodesk.com/blog/autodesk-ember-3d-printer-source-cad-design-files

Source and more information:

http://spark.autodesk.com/blog/embers-mechanical-designs-are-now-open-source

Hack your FDM Delta into DLP 3D printer

As I was researching low cost DLP solutions I found this project by sirocco where he converted his old Delta into DLP SLA 3d printer by putting a projector on the top opening and adding vat resin. Delta configuration looks like good option due to hight.

I'm not sure how he moves his vat with salt water and resin, it could be done by separate mechanism or by some type of vat tray mounted on three points to the Delta frame and moved by existing motors.



Source, more details, but no clear instructions:

http://www.instructables.com/id/Delta-Robot-to-Sla-Printer-Top-Down/

Print results look decent:



Hacking Autodesk Ember

Here is a compilation of tutorials on how to hack and tweak your Autodesk Ember DLP 3d printer. It is interesting to see that this machine made by a major corporation can be easily open and tinkered with.

Accessing the control electronics block and USB to control the LCD projector




As always you do this on your own risk! Warranty will probably be voided. 


Here is a tutorial on how to increase power of Embers motors, unstuck frozen prints with brute force and make full volume printing easier. Motors will probably have shorter life span. Basic knowledge of electronics is needed.

http://www.instructables.com/id/Supercharge-Your-Ember/

How to access and control Embers internal Wintech projector via USB for more power and control. In theory it should enable higher speeds. This tutorial also goes into drivers and software.

http://www.instructables.com/id/Setting-Ember-for-More-POWER-or-how-to-control-the/

Here is some research and testing on how will the PDMS tray window clouding influence exposure time:

http://www.instructables.com/id/Window-clouding-in-the-Ember-printer/

... and to maintain the Ember resin tray: http://www.instructables.com/id/Resin-Tray-Care/

If you want to use different resins in Autodesk Ember, here is a guide on how to set it up and calibrate it:

http://www.instructables.com/id/How-to-tune-Embers-print-settings-for-new-resins/

... and to calibrate the head: http://www.instructables.com/id/How-to-Calibrate-Embers-Print-Head/

Here is simple guide on how to update Embers firmware:

http://www.instructables.com/id/How-to-update-Embers-firmware/

You can find several more on Instructables: http://www.instructables.com/howto/ember/

How to upgrade Ember's motor control and front panel:

http://www.instructables.com/id/Upgrading-Embers-Motor-Board-and-Front-Panel/

Here is a guide on how to disassemble Ember build arm:

http://www.instructables.com/id/Ember-3D-Printer-Build-Arm-Teardown/

If you have any problems and want to remove the Ember projector here is detailed instruction page:

http://www.instructables.com/id/How-to-Remove-Embers-Projector/


There is also a way to get sub-pixel resolution on Ember which could also probably work on other DLP 3d printers. Here is the explanation video:




Here is the Instructables tutorial: http://www.instructables.com/id/Ember-Printer-How-a-Voxel-Grows/


Autodesk Ember SLA 3d printer review and maintenance by Adafuit

Ruiz brothers from Adafruit did a very useful review and operations manual for Autodesk Ember SLA 3d printer. They go trough many aspect of it including basic maintenance and Hall sensor troubleshooting.

Basic review of Ember:




More detailed guide, operations manual and usage tips:




Here is a very detailed guide on how to use Ember, basic maintenance and even how to repair the Hall sensor so you can align the printer:

https://learn.adafruit.com/ember-3d-printer

Here are some guides on how to hack Autodesk Ember.

Always wear gloves when working with resin

How to build the cheapest DLP SLA 3d printer for under 500$ including projector

This is probably the cheapest DLP SLA 3D printer that you can build yourself for some 500 USD including the projector!

"Little Dipper" has a simple design that anyone can replicate with some basic DIY skills and it makes prints with reasonable quality.
The most expenisve par is the projector which you can get dfor some 350 USd new, but you could probably get it used somewhere. Other parts include simple z axis movement (screw or belt driven) on wood frame and Ramps 1.4 or Arduino controlled electronics.

Simple plastic vat and z axis screw drive

Objects 3d printed on Little Dipper

Objects 3d printed on Little Dipper. You can see the layers, but the quality is still great for the price.

Objects 3d printed on Little Dipper


Little Dipper DIY DLP Sla 3d printer. You can see all the elements with DLP projector on top.

Here is the project description from the makers:

How it works?
A DLP projector is used to cure UV setting resin one layer at a time while a moving axis drops incrementally into the vat of resin. A projected slice cures each layer and builds the part. This style of resin printer is different from a FormLabs 3D printer and some others in two ways.
  1. It uses a DLP projector rather than a laser to cure each layer.
  2. It shines the light source from the top rather than up from the bottom.
Advantages over laser based bottom up and DLP bottom up designs:
  • Simplicity
  • Lower start-up cost
  • Modifiable to bottom up
  • Fast build (~1 evening)
Major Components and Materials:

DLP projector

There are 2 known choices, although others may work.
  1. Acer P1283 DLP Projector
  2. Acer H6510BD DLP HD projector
Linear Slide/Axis

Almost any linear axis that is belt driven or screw driven will work. Project uses a minimal version of this:
http://www.openbuilds.com/builds/v-slot-lead-screw...
A more budget minded and adventurous person could even choose a drawer slide, but you may find that rigidity and smooth sliding in the z-axis will be a useful feature.

4x4 sheet of 1/2in MDF or equivalent material and hardware

The version shown here is as simple as it gets. 2 pices of MDF cut to provide a mount for the axis, projector and stable footing for the machine. Pretty much any kind of enclosure can be designed for this 3D printer. Your main objective is frame rigidity and ambient light blocking.

Ramps 1.4 or Arduino based electronics capable of running at least (1) nema 17 stepper motor
This build features a RAMPS 1.4 board, stepper drivers and an Arduino Mega 2650 with standard Sprinter firmware. There are some basic modifications needed depending on the hardware you choose. None of these modifications constitute needing to know anything in-depth about programming. The firmware used is modified for 5/16 standard threaded rod and has end-stops disabled. You can modify this firmware using the Arduino environment to further suit your needs.

UV Resin

Makerjuice.com, Madesolid.com are the two most seemingly popular and affordable options for UV resin suitable for DIY resin printers such as the one featured in this build. This build has been tested with G+ from Makerjuice. Funtodoo, Form1+ and Spark/Ember resin formulations are likely suitable.

Build Platform and Plastic Tupperware vat

This build includes plans for a build platform that fits a specific set of Tupperware available at "wallyworld". The benefit to the type chosen in this build is that you get a variety of sizes that scale easily, so that extensive design modifications are not needed. You will also need additional containers for post-cure/clean up of your resin parts.

Control Software and Slicer

Creation workshop is used to control and slice 3D models. Download Creation Workshop here.


Here is Instructables page of a project with detailed build guide, software and everything nneded to build it:

http://www.instructables.com/id/Little-Dipper-SLADLP-3D-printer-for-under-500-proj/

This project was developed by Instructables user "marshallpeck". Kudos to you sir! You can also see more at: https://www.facebook.com/protobuilds/ or http://protobuilds.com/ .

All the recent developments in SLA 3d printing make me think that it is the future for home and hobby 3d printing. We need more affordable resin materials and more low cost parts.

UPDATE:

Thanks to Reddit commentator "Panaetius" here is a link where you can start to research on how to hack or prepare a DLP projector for using it for SLA 3d printing. It describes basic concepts and example of modifications to color wheel focus / lens mechanism and UV filters.

http://www.os-rc.com/en/ilios-documentation-page/37-11-projector-modifications

UPDATE:

Chimera is even cheaper SLA DLP machine made from second-hand and scrpa parts for under 60USD:

http://diy3dprinting.blogspot.com/2015/10/chimera-dlp-3d-printer-you-can-build.html




Autodesk makes their Ember PR48 resin open source

In an unusual move for such big corporation Autodesk has made their PR48 resin recipe open source.
Kudos Autodesk! They even announced that they will make their Ember DLP 3d printer open source also.
It is licensed under http://creativecommons.org/licenses/by-sa/4.0/

Here are the reasons for open sourcing it from the source webpage:
  • We have an open approach, and encourage the use of 3rd-party materials in our printer. We include 3rd-party materials in the defaults for Ember's online model preparation and slicer, and are adding more as we optimize their settings for Ember: you can check them out at emberprinter.com. (You don't actually need an Ember to use the site.) This Instructable describes how to test new resins:
  • Autodesk is thinking differently about 3D printing, and sharing under an license reflects our commitment.
  • Open sourcing our resin formulation is only the first step in the journey of opening our 3D printer and our Spark 3D printing platform.
Here are the ingredients:
  • Photoinitiator: 2,4,6-Trimethylbenzoyl-diphenyl-phosphineoxide (TPO) 0.40%
  • UV blocker: 2,2’-(2,5-thiophenediyl)bis(5-tert-butylbenzoxazole) (OB+) 0.16 %
  • Reactive diluent: Genomer 1122 19.89%
  • Oligomer: Ebecryl 8210 39.78%, Sartomer SR 494 39.77%
Are those ingredients even available for open sale?

You can learn more on Spark blog:

http://spark.autodesk.com/blog/embers-resin-now-open-source




Huge moves in the industry ... will this Spark the  DLP 3d printers revolution?

Loafinator simple DIY vibration cleaning bath for your resin 3d printed objects

Christopher Barr wanted to make a 20 minute post SLA printing cleaning process of isopropyl alcohol (IPA) bath shorter so he made this simple DIY vibration cleaning bath that decreases the time by tenfold and makes it into two minute process.

In the core of the machine that produces vibrations is a common hand sander (in this case Makita) that is fixated by putting it in expanding urethane foam mold. The base and the top container are made from two simple loaf pans (hence: the Loafinator).









You can see more details and small build log on FormLabs forum:

http://forum.formlabs.com/t/introducing-the-loafinator/3638


Here is the video of Loafinator  working:

FormLabs wants to rule in 2015 and they demonstrate it with a fully resin 3d printed speaker project

FormLabs has some resolutions for 2015 and they have made a fully 3d printable speaker project made from resins with different properties. Key resin property for the speaker is flexibility. Improved resolution and optimized support systems help also.



You can learn more at:

http://formlabs.com/en/company/blog/2015/01/06/new-year-new-resolution/

Here is the SLA printed DIY speaker developed by Adam Lebovitz made with various resins:


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