3D Printer Tool Changer Gives You Access to Lots of Extruders

The benefits of having a 3D printer with multiple extruders are numerous: you can print soluble support material for easy removal, print a combination of flexible and rigid filament, or simply print in different colors. Unfortunately, traditional multi-extruder setups have some serious drawbacks, even aside from the cost.

Usually, the extruders are all mounted next to each other on a single carriage. This increases the mass, which can cause print quality issues like shadowing. It also reduces the printable area, as each extruder needs to be able to reach the entire area. All of this means that the design becomes more and more impractical with each extruder you add, and that’s why it’s uncommon to see more than two extruders on a printer.

Over on Hackaday.io, [rolmie] has come up with a very practical (and affordable) solution to this problem. He has designed a tool changer that gives the printer the ability to switch out hot ends on the fly. The system is very similar to the tool changers we see on CNC machining centers: tools (the hotends) are stored on a rack, and a tool change in the G-code sends the carriage over to the rack to drop off the old hotend and pick up a new one.

The benefit of the design is that both the mass and volume of the carriage are kept to a minimum, while allowing you to use many different hot ends. Each hotend’s settings can be configured individually, and you can even use different models of hotend altogether (maybe one model works better for PLA, while another is better for ABS). The design is still in the prototyping stage and needs some refinement, but it’s a very promising proof of concept that seems like it could be implemented fairly easily into most 3D printer models.

Continue reading “3D Printer Tool Changer Gives You Access to Lots of Extruders”

Additive + Subtractive = One Powerful Machine

It says it right on the title of the video below: it was bound to happen eventually. It’s only natural that somebody would stick a 3D printer extruder on the business end of a CNC machine. The long-awaited convergence of additive and subtractive manufacturing is here.

OK, that may be overstating things a bit, but we think [Chris DePrisco] is on to something here. Given the considerable investment he’s made in his DIY CNC machine, an enormous vertical machining center that looks a little like a homebrew Bridgeport, it was a no-brainer to take advantage of the huge XYZ stage. Mounting the Titan Aero extruder to the quill required some custom parts; fair warning that the video below is heavy on machining, but it’s not the seven hours of video he streamed when he milled the heated aluminum bed. Skip ahead to about the six-minute mark if you want to see the first prints and how he optimized the setup.

As we watched [Chris]’ video, we were struck by the potential for adding 3D printing to CNC milling machines. What we’d like to see is a setup where the spindle and the extruder work together to build more complex parts. Or maybe a tool-changing CNC that can pick up a spindle, an extruder, and maybe even a laser or plasma cutter head. Now that would be a powerful machine!

Continue reading “Additive + Subtractive = One Powerful Machine”

MRRF 17: E3D Introduces Combination Extruder And Hotend

Since the beginning of time, or 2006, the ‘hot glue gun’ part of our CNC hot glue guns have had well-defined parts. The extruder is the bit that pushes plastic through a tube, and the hot end is where all the melty bits are. These are separate devices, even though a shorter path from the extruder to hotend is always better. From Wade’s gear extruder to a nozzle made from an acorn nut, having the hotend and extruder as separate devices has become the standard.

This week at the Midwest RepRap Festival, E3D unveiled the Titan Aero. It’s an extruder and hotend rolled into one that provides better control over the filament, gives every printer more build height, and reduces the mass of a 3D printer toolhead.


The aluminum thermal block of the Titan Aero

The Titan Aero, revealed on the E3D blog yesterday, is the next iteration of E3D’s entry into the extruder market. It’s a strange mashup of their very popular V6 hotend, with the heat break coupled tightly to the extruder body. A large fan provides the cooling, and E3D’s thermal simulations show this setup will work well.

The core component of the Aero extruder is a fancy and complex piece of milled aluminum. This is the heatsink for the extruder and provides the shortest path possible between the hobbed gear and the nozzle. This gives the Aero better control over the extrusion of molten plastic and makes this the perfect extruder and hotend setup for hard to print materials.

Combine the Aero with a smaller ‘pancake’ stepper motor, and you have a very small, very light hotend and extruder. This makes it perfect for the small printers we’re so fond of and for printers built for fast acceleration. I can easily see a few end effectors for Delta-style printers built around this extruder in the near future.

E3D’s Volcano nozzle sock

Also at the E3D booth were a few prototypes of nozzle socks. Late last year, E3D released silicone nozzle covers – we’re calling them nozzle socks – for their V6 hotend. These are small silicone covers designed to keep that carbonized crap off of your fancy, shiny hotend. It’s not something that’s necessary for a good print, but it does keep filament from sticking to your hotend, and you get the beautiful semantic satiation of saying the words nozzle socks.

E3D’s other hotend, the Volcano, a massive and powerful hotend designed to push a lot of plastic out fast, did not get its own nozzle sock at the time. Now, the prototypes are out, and the E3D guys expect them to be released, ‘in about a month’.

DIY Syringe Pump Saves Big Bucks for Hacker’s Lab

If you had a choice between going to your boss and asking for funds for a new piece of gear, would you rather ask for $3000 to buy off-the-shelf, or $200 for the parts to build the same thing yourself? Any self-respecting hacker knows the answer, and when presented with an opportunity to equip his lab with a new DIY syringe pump for $200, [Dr. D-Flo] rose to the challenge.

The first stop for [Dr. D-Flo] was, naturally, Hackaday.io, which is where he found [Naroom]’s syringe pump project. It was a good match for his budget and his specs, but he needed to modify some of the 3D printed parts a little to fit the larger syringes he intended to use. The base is aluminum extrusion, the drive train is a stepper motor spinning threaded rod and a captive nut in the plunger holders, and an Arduino and motor shield control everything. The drive train will obviously suffer from a fair amount of backlash, but this pump isn’t meant for precise dispensing so it shouldn’t matter. We’d worry a little more about the robustness of the printed parts over time and their compatibility with common lab solvents, but overall this was a great build that [Dr. D-Flo] intends to use in a 3D food printer. We look forward to seeing that one.

It’s getting so that that you can build almost anything for the lab these days, from peristaltic pumps to centrifuges. It has to be hard to concentrate on your science when there’s so much gear to make.

Continue reading “DIY Syringe Pump Saves Big Bucks for Hacker’s Lab”

Think Globally, Build Locally With These Open-Source Recycling Machines

Walk on almost any beach or look on the side of most roads and you’ll see the bottles, bags, and cast-off scraps of a polymeric alphabet soup – HDPE, PET, ABS, PP, PS. Municipal recycling programs might help, but what would really solve the problem would be decentralized recycling, and these open-source plastics recycling machines might just jump-start that effort.

We looked at [Precious Plastic] two years back, and their open-source plans for small-scale plastic recycling machines have come a long way since then. They currently include a shredder, a compression molder, an injection molder, and a filament extruder. The plans specify some parts that need to be custom fabricated, like the shredder’s laser-cut stainless steel teeth, but most can be harvested from a scrapyard. As you can see from the videos after the break, metal and electrical fabrication skills are assumed, but the builds are well within the reach of most hackers. Plans for more machines are in the works, and there’s plenty of room to expand and improve upon the designs.

We think [Precious Plastic] is onto something here. Maybe a lot of small recyclers is a better approach than huge municipal efforts, which don’t seem to be doing much to help.  Decentralized recycling can create markets that large-scale manufacturing can’t be bothered to tap, especially in the developing world. After all, we’ve already seen a plastic recycling factory built from recycled parts making cool stuff in Brazil.

Continue reading “Think Globally, Build Locally With These Open-Source Recycling Machines”

MRRF: Innovating Extruders and Dissolvable Filament

Think laying down molten plastic on a 3D printer is as easy as squeezing plastic filament out of a hot tube? It’s not, and anyone who had a 3D printer in 2009 would tell you as such. There were hobbed bolts that stripped the plastic into a gooey paste, extremely large x carriages that made everything wobbly, and nothing worked as well as it does today.

Technology marches on, and this year’s Midwest RepRap Festival had people showing off the latest advances in pushing plastic, and something that hasn’t seen much use yet – dissolvable filament.

Continue reading “MRRF: Innovating Extruders and Dissolvable Filament”

3D Printing Pen and CNC Machine Yields Cheap 3D Printer

3D printers are ubiquitous now, but they’re still prohibitively expensive for some people. Some printers cost thousands, but even more inexpensive options aren’t exactly cheap. [Daniel] decided that this was unacceptable, and set out to make a basic 3D printer for under $100 by including only the bare essentials needed for creating anything out of melted plastic.

3D printers are essentially four parts: a bed, filament, and a hot end and extruder. In a previous project, [Daniel] used parts from old CD drives to create a three-axis CNC machine which he uses for the bed. To take care of the hot end and extruder, he is using a 3D printing pen which he mounts to the CNC machine and voila: a 3D printer!

It’s not quite as simple as just strapping a 3D printing pen to a CNC machine, though. The pen and the CNC machine have to communicate with each other so that the pen knows when to place filament and the CNC machine knows when to move. For that, [Daniel] went with a trusty Arduino in order to switch the pen on and off. Once it’s working, it’s time to start printing!

[Daniel] does note that this is a design that’s relatively limited in terms of print size and resolution, but for the price it can’t be beat. If you’re interested in getting started with 3D printing, a setup like this would be perfect. 3D pens are a pretty new idea too, and it’s interesting to see them used in different ways like this.