Dynamic Build Platforms For 3D Printers Remove Supports And Save Material

April 10, 2021 by Bob Baddeley 31 Comments

We’re all too familiar with the 3D printing post-processing step of removing supports, and lamenting the waste of plastic on yet another dwindling reel of filament. When the material is expensive NinjaFlex or exotic bio-printers, printing support is downright painful. A group at USC has come up with a novel way of significantly reducing the amount of material that’s 3D printed by raising portions of the bed over time, and it makes us wonder why a simpler version isn’t done regularly.

In the USC version, the bed has a bunch of square flat metal pieces, with a metal tube underneath each. The length of the tube determines the eventual height of that square. Before the print is made, the bed is prepared by inserting the appropriate length tubes in the correct squares. Then, during the print, a single motor pushes a platform up, and based on the height of the pin, that portion of the bed raises appropriately, then stops at the right height.

This is a significant savings over having a matrix of linear motors or servos to control each square, at the cost of having to prepare the pins for each print.

But it has us wondering; since CURA and other slicing software have the ability to pause at height, what if the slicing software could allow for the placement of spacer blocks of a known size? The user would have a variety of reusable spacer blocks, and position them in the software, and the slicer would build the support material starting on top of the block. It could print a rectangle on the base layer to aid in proper placement of the blocks during printing, and pause at the correct heights to let the user insert the blocks. At the end of the print a lot less support material has been used.

For situations where you want to leave your print to run unattended, or if the cost of the material is low enough that it doesn’t justify the effort, then maybe this isn’t worth it. Another problem might be heating that platform, though since only support material will be printed on it, some curling won’t matter much. What do you think?

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3D Printer As Robot: The Functograph

April 3, 2021 by Al Williams 12 Comments

A 3D printer is really a specialized form of robot. Sure, it isn’t exactly Data from Star Trek, but it isn’t too far from many industrial robots. Researchers from Meiji University made the same observation and decided to create a 3D printer that could swap a hot end for other types of robotic manipulators. They call their creation the Functgraph. (Video, embedded below.)

Some of the tasks the Functgraph can do including joining printed parts into an assembly, breaking support material, and more. The surprise twist is that — unlike traditional tool change schemes — the printer prints its own end effectors together with the print job and picks them up off the build plate.

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JIT Vs. AM: Is Additive Manufacturing The Cure To Fragile Supply Chains?

April 1, 2021 by Dan Maloney 46 Comments

As fascinating and frustrating as it was to watch the recent Suez canal debacle, we did so knowing that the fallout from it and the analysis of its impact would be far more interesting. Which is why this piece on the potential of additive manufacturing to mitigate supply chain risks caught our eye.

We have to admit that a first glance at the article, by [Davide Sher], tripped our nonsense detector pretty hard. After all, the piece appeared in 3D Printing Media Network, a trade publication that has a vested interest in boosting the additive manufacturing (AM) industry. We were also pretty convinced going in that, while 3D-printing is innovative and powerful, even using industrial printers it wouldn’t be able to scale up enough for print parts in the volumes needed for modern consumer products. How long would it take for even a factory full of 3D-printers to fill a container with parts that can be injection molded in their millions in China?

But as we read on, a lot of what [Davide] says makes sense. A container full of parts that doesn’t arrive exactly when they’re needed may as well never have been made, while parts that are either made on the factory floor using AM methods, or produced locally using a contract AM provider, could be worth their weight in gold. And he aptly points out the differences between this vision of on-demand manufacturing and today’s default of just-in-time manufacturing, which is extremely dependent on supply lines that we now know can be extremely fragile.

So, color us convinced, or at least persuaded. It will certainly be a while before all the economic fallout of the Suez blockage settles, and it’ll probably longer before we actually see changes meant to address the problems it revealed. But we would be surprised if this isn’t seen as an opportunity to retool some processes that have become so optimized that a gust of wind could take them down.

Speaker Is Fully 3D Printed

March 25, 2021 by Al Williams 11 Comments

[Thomas] is always up to some kind of 3D printing project. His latest? A fully 3D printed speaker. This is possible because of designs by [Paul Ellis] that use 3D printed materials for nearly all parts of the speaker. You can see and hear the speaker in the video below.

You might expect different parts of the speaker use different filaments. There are also different techniques such as the use of single-wall printing that makes the speaker possible.

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PCTG Filament Has Interesting Properties

March 24, 2021 by Al Williams 37 Comments

Early 3D printers used ABS, but bad fumes and warping made most people go to PLA. However, PETG has a lot of the great properties of ABS along with some of the ease-of-use of PLA. According to a recent [VisionMiner] video, however, PCTG — Polyethylene Terephthalate-Glycol — could be the next filament of choice. The filament itself is from Essentium, but it appears that [VisionMiner] is a reseller of the filament (along with other engineering plastics). Thus the video below has a bit of marketing speak in it, but it also has good information and examples of using PCTG.

The plastic is relatively inexpensive, but still not as cheap as PLA or even PETG. A 750g roll is about $40 The benefits? According to the video, this plastic is stronger, tougher, and clearer than other common options.

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Photorender Your 3D Models

March 15, 2021 by Al Williams 7 Comments

Of course, you’ll want to take your latest 3D design and print it so you’ll have a physical object. But in some cases, you’d like to have a rendering of it. If you use OpenSCAD, FreeCAD, or most other CAD programs you can get a simple rendering of your object, but what if you want something that looks real? [Teaching Tech] shows how you can use a website, Vectary, to get realistic photo renderings of your 3D models. (Video, embedded below.) The free plan has a few limits, but nothing that should bother most people.

Vectary is sort of like a super version of TinkerCad with a lot of options for realistic modeling and augmented reality. Some of the more advanced features are behind a subscription plan, but for what [Teaching Tech] is showing, you can use the free plan.

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3D Printer Air Compressor Is A Wankel

March 11, 2021 by Al Williams 31 Comments

We wonder if mechanics are as annoyed when we say “engine” as we get when someone talks about a “computer” or a “radio.” Sure, you know what all three of those words mean, but there are many different kinds of radios, computers, and engines. In [3DprintedLife’s] case, he made a compressed air engine of the Wankel style.

The Wankel — a rotary engine — is most famous for its use in some Mazda cars. If you’ve done a lot of 3D printing, you know that creating an air-tight piston on a 3D printer is no mean feat. Of course, he didn’t do it right off the bat. It took what looks like a number of iterations to get it going, and he shares some of what he learned doing this project.

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