3D Printing With Clay, Thanks To Custom Extruder

August 22, 2023 by Donald Papp 14 Comments

When it comes to 3D printing clay, there are a lot of challenges to be met. An extruder capable of pushing clay is critical, and [davidsfeir] has an updated version suitable for an Ender 3 printer. This extruder is based on earlier designs aimed at delta printers, but making one compatible with an Ender 3 helps keep things accessible.

Lightly pressurized clay comes in via the clear tube. Air escapes out the top (motor side) while an auger homogenizes the clay and pushes it out the nozzle.

What’s special about a paste extruder that can push clay? For one thing, clay can’t be stored on a spool, so it gets fed into the extruder via a hose with the help of air pressure. From there, the clay is actually extruded with the help of an auger that takes care of pushing the clay down through the nozzle. The extruder also needs a way to deal with inevitable air bubbles, which it does by allowing air to escape out the narrow space at the top of the assembly while clay gets fed downward.

[davidsfeir] was greatly inspired by the work of clay-printing pioneers [Piotr Waśniowski] and his de-airing clay extruder, and [Jonathan Keep], who has documented 3D printing with clay comprehensively in a freely-available PDF. You can check out more of [david]’s designs on his Instagram page.

There are so many different aspects to printing with clay or clay-like materials that almost every part is ripe for innovation. For example, we’ve seen wild patterns result from sticking a thumping subwoofer under a print bed.

Hackaday Prize 2023: One-Handed Soldering With The Solder Sustainer

August 4, 2023 by Dan Maloney 48 Comments

For a lot of us, soldering has become so ingrained that it’s muscle memory. We know exactly when the iron is hot enough, how long to leave the tip in contact with the joint to heat it up, and exactly where to dab in the solder to get it to flow. When you’re well-practiced it can be a beautiful thing, but for those who don’t do it frequently, soldering can be frustrating indeed.

The “Solder Sustainer” looks like it just might be aimed at solving that problem, as well as a few others. It comes to us from [RoboticWorx], and while it looks a little like the love child of a MIG welder and a tattoo machine, it’s got a lot going for it. The idea is to make soldering a one-handed task by combining the soldering iron and a solder wire feeder into one compact package. The solder feeder is very reminiscent of a filament extruder on a 3D printer, using a stepper to drive spring-loaded pinch wheels, which forces the solder down a curved 3D-printed tube that directs it toward the tip. The pancake stepper is driven by an ESP32, which also supports the touch sensor that lets you advance the solder. The whole thing can be powered off a USB-C power supply, or using the onboard USB charger that can be connected in line with the soldering iron supply.

The video below shows Solder Sustainer in use. Yes, we know — some of those joints look a little iffy. But that seems to have more to do with technique than with the automatic solder feed. And really, in situations where you’ve previously wished for a third hand while soldering, this would probably be just the thing.

The Solder Sustainer is an entry in the “Gearing Up” round of the 2023 Hackaday Prize. If you’ve got an idea for a tool, jig, fixture, or instrument that makes hacking easier, we want to know about it. But you’d better hurry — the round ends on August 8.

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A Paste Extruder For Normal Printers

May 15, 2023 by Jenny List 17 Comments

In the bright sunshine of a warm spring afternoon at Delft Maker Faire, were a row of 3D printers converted with paste extruders. They were the work of [Nedji Yusufova], and though while were being shown printing with biodegradable pastes made from waste materials, we were also interested in their potential to print using edible media.

The extruder follows a path set by similar ones we’ve seen before in that it uses a disposable syringe at its heart, this time in a laser-cut ply enclosure and a lead screw driven by a stepper motor. It’s part of a kit suitable for run-of-the-mill FDM printers that’s available for sale if you have the extra cash, but happily they’ve also made all the files available.

We’ve seen quite a few syringe extruders and at least one food printer, so there’s nothing particularly new about this one. What it does give you is a relatively straightforward build and a ready integration with some mass market printers you might be familiar with. Perhaps the most interesting part of this project isn’t even the extruder itself but the materials, after all having a paste extruder gives you the opportunity to experiment with new recipes. We like it.

Cocoa Press Chocolate 3D Printer Offered As DIY Kit

May 1, 2023 by Tom Nardi 19 Comments

Ultimately, the goal of Hackaday is to shine a light on the incredible projects coming from the hardware hacking community. In the vast majority of cases, said projects end up being one-off creations — a clever solution that solved a specific problem for the creator, which may or may not be directly applicable to anyone else. But occasionally, perhaps one in every few thousand projects, we see an idea that’s compelling enough to become a commercial product.

Today, we’re happy to add the Cocoa Press to that list. Creator [Ellie Weinstein] has recently unveiled a commercialized version of the chocolate 3D printer she’s been working on for several years, and true to the maker spirit, it’s being offered as a DIY kit. You can currently put a $100 USD deposit on the final product, which is expected to ship before the end of the year. Assembly time is estimated to be around 10 hours and no previous experience with building 3D printers is required, though we’re sure it wouldn’t hurt.

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Extrusion For The Pottery Shop

January 20, 2023 by Bryan Cockfield 2 Comments

Extrusion is a process for forming materials by forcing them through an opening, which can allow for complex shapes. Aluminum extrusion beams are what most of us are probably thinking of, but plenty of other things are made from extruded material like pipe, heat sinks, and even macaroni. Extrusion can also be used for modelling clay to create uniform sections of rounded clay as a starter material for producing other pottery, and [Justins Makery] has built a custom extruder to do just that.

The build starts with welding together a metal frame to hold the press, and uses a wooden wagon handle to drive the extruder. The handle can be moved up or down the frame to increase the range of motion thanks to a custom bearing and slots cut into the frame’s post. The piston mechanism itself is built out of aluminum plate with a cylinder loosely fitted to it to allow for easy cleaning, and the top of the piston uses a loose-fitting plastic cap cut out of an old cutting board.

With everything in pace, the extruder can make cylinders of clay of any desired thickness thanks to swappable dies. While it doesn’t produce the end result of the workshop directly, it definitely helps to provide the potter with clay of uniform dimensions used for building other pieces of pottery, much like how aluminum extrusions are used to build all kinds of other things as well.

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PET Bottles Diligently Turned Into Filament

August 25, 2022 by Bryan Cockfield 21 Comments

While the price of 3D printers has come down quite a lot in the past few years, filament continues to be rather pricey especially for those doing a lot of printing. This has led to some people looking to alternatives for standard filament, including recycling various forms of plastic. We’ve seen plenty of builds using various materials, but none so far have had this level of quality control in the final project.

What sets this machine apart from others is that it’s built around an Arduino Nano and includes controls that allow the user to fine-tune a PID controller during the conversion of the recycled plastic into filament. Different plastic bottles have different material qualities, so once the machine is started it can be adjusted to ensure that the filament produced has the exact specifications for the printer. The PCB is available for download, and the only thing that needs to be done by hand besides feeding the machine to start it is to cut the plastic into strips for the starter spool. There is also a separate 3D printed tool available to make this task easy, though.

Not only could this project save printing costs, but it also keeps harmful plastics out of landfills and other environments. Recycling plastic tends to be quite difficult since producing new plastic is incredibly cheap, and the recycled material can’t be used as often as other materials such as aluminum. But there are still plenty of people out there trying to reuse as much of it as they can.

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Large Format 3D Printer Is A Serious Engineering Challenge

July 27, 2022 by Danie Conradie 14 Comments

When you want to build a large format 3D printer, you can’t just scale up the design of a desktop machine. In an excellent four-part build series (videos after the break), [Dr. D-Flo] takes us through all the engineering challenges he had to contend with when building a 3D printer with a 4x4x4 ft (1.2 m cube) print volume.

For such a large print volume you won’t be printing with a 0.4 mm nozzle. The heart of the printer is a commercial Massive Dimension MDPH2 pellet extruder, capable of extruding ~1 kg of plastic per hour through 1.5 mm to 5 mm nozzles. To feed the extruder, [Dr. D-Flo] used a Venturi vacuum system to periodically suck pellets from a large hopper. The system is driven by compressed air, which can introduce moisture back into the carefully dried pellets. To reduce the humidity levels, the compressed air passes through a series of vertical aluminum tubes to allow moisture to condense and drain out the bottom.

At 8.4 kg, it needs a powerful motion platform to move it. [Dr. D-Flo] went with a stationary bed design, with the extruder pushed around by seven high torque NEMA23 motors on a large gantry built from C-beam aluminum extrusions. A machine this size needs to be very rigid with well-fitting parts, so [Dr. D-Flo] made heavy use of CNC machined aluminum parts.

To allow dynamic bed leveling, [Dr. D-Flow] made use of a Quad Gantry Leveling (GQL) scheme. This means that each of the four Z-actuators will dynamically adjust its position based on inputs from the leveling probe. The avoid stressing the corner mountings that hold the X-Y gantry to the Z carriage plates, he used radial spherical bearings at the mounting points to allow a few degrees of play.

The build plate consists of an aluminum plate bolted onto the base in 25 positions with springs for adjustability. A massive 6000 watt 220 V heating pad sticks to the bottom, while the actual printing surface is a large sheet of borosilicate glass. One major concern was the deflection of the build plate when heated to working temperature, but with all the adjustment options [Dr. D-Flo] was able to get height variation down to about 0.25 mm. This is within the acceptable range when printing with layer heights of 1 mm or more.

We’ve featured large scale 3D printers in the past, but none are quite as big the University of Maine’s building-sized 3D printer that can print a motorboat in one piece.

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