μRepRap: Taking RepRap Down To Micrometer-Level Manufacturing

When the RepRap project was started in 2005 by [Dr Adrian Bowyer], the goal was to develop low-cost 3D printers, capable of printing most of their own components. The project slipped into a bit of a lull by 2016 due to the market being increasingly flooded with affordable FDM printers from a growing assortment of manufacturers. Now it seems that the RepRap project may have found a new impetus, in the form of sub-millimeter level fabrication system called the μRepRap as announced by [Vik Olliver] on the RepRap project blog, with accompanying project page.

The basic technology is based around the OpenFlexure project’s Delta Stage, which allows for very precise positioning of an imaging element, or conceivably a fabrication tool. As a first step, [Vik] upgrade the original delta stage to a much reinforced one that can accept larger NEMA17 stepper motors. This also allows for standard 3D printer electronics to control the system much like an FDM printer, only at much smaller scales and with new types of materials. The current prototype [Vik] made has a claimed step accuracy of 3 µm, with a range of tools and deposition materials being considered, including photosensitive resins.

It should be noted here that although this is a project in its infancy, it has solid foundations due to projects like OpenFlexure. Will μRepRap kickstart micrometer-level manufacturing like FDM 3D printing before? As an R&D project it doesn’t come with guarantees, but color us excited.

Thanks to [Tequin] for the tip.

Marionette 3D Printer Replaces Linear Rails With String

In the early days of FDM 3D printing, the RepRap project spawned all sorts of weird and and wonderful designs. In the video after the break [dizekat] gives us a throwback to those times with the Marionette 3D printer, completely forgoing linear rails in favor of strings.

The closest thing to a linear guide found on the Marionette is a pane of glass against which the top surface of the print head slides. A pair of stepper motors drive the printhead in the XY-plane, similar in concept to the Maslow CNC router, but in this case two more strings are required to keep the mechanism in tension. To correctly adjust the length of the string across the full range of motion, [dizekat] uses a complex articulating pulley mechanism that we haven’t seen before. The strings are also angled slightly downward from the spool to the print head, holding it in place against the glass.

The bed print bed is also suspended and constrained using string, with no rigid mechanical member attaching it to the frame of the printer. Six strings connected to the sides and bottom of the bed frame constrain it in 6-DOF, and pass through another pulley arrangement to three more strings and finally to a single stepper driven belt.

We can’t see any particular advantage to forgoing the linear rails, especially when the mechanisms have to be this complex, but it certainly make for an interesting engineering challenge. Whatever the reason, the end result is fascinating to watch move, and the print quality even looks decent.

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The underside of the rotational base of the Gen5X 3D printer. A belt connects a pulley on the bottom of the stage to a stepper motor on the right side. The carriage for the stage looks organic in nature and is printed in bright orange PLA. The stage can rotate within the carriage which is mounted on two stainless steel rods connected to teal mounting points on either side of the printer (ends of the X-axis).

5-Axis Printer Wants To Design Itself

RepRap 3D printers were designed with the ultimate goal of self-replicating machines. The generatively-designed Gen5X printer by [Ric Real] brings the design step of that process closer to reality.

While 5-axis printing is old hat in CNC land, it remains relatively rare in the world of additive manufacturing. Starting with “a set of primitives… and geometric relationships,” [Real] ran the system through multiple generations to arrive at its current design. Since this is a generative design, future variants could look different depending on which parameters you have the computer optimize.

The Gen5X uses the 5 Axis Slicer from DotX for slicing files and runs a RepRap Duet board with Duex expansion. Since the generative algorithm uses parametric inputs, it should be possible to to have a Gen5X generated based on the vitamins you may have already. With how fast AI is evolving, perhaps soon this printer will be able to completely design itself? For now, you’ll have to download the files and try it yourself.

If you want to see some more printers with more than 3-axes, check out the RotBot or Open5X.

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Image Credit: https://3dp.se/2018/04/17/3dmeetup-lockade-entusiaster-i-alla-aldrar/

Remembering Sanjay Mortimer, Pioneer And Visionary In 3D Printing

Over the weekend, Sanjay Mortimer passed away. This is a tremendous blow to the many people who he touched directly and indirectly throughout his life. We will remember Sanjay as pioneer, hacker, and beloved spokesperson for the 3D printing community.

If you’ve dabbled in 3D printing, you might recall Sanjay as the charismatic director and co-founder of the extrusion company E3D. He was always brimming with enthusiasm to showcase something that he and his company had been developing to push 3D printing further and further. But he was also thoughtful and a friend to many in the community.

Let’s talk about some of his footprints.

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Prusa XL Goes Big, But That’s Only Half The Story

For a few years now it’s been an open secret that Prusa Research was working on a larger printer named, imaginatively enough, the Prusa XL. Positioned at the opposite end of their product spectrum from the wildly popular Prusa Mini, this upper-tier machine would be for serious hobbyists or small companies that need to print single-part objects that were too large for their flagship i3 MK3S+ printer. Unfortunately, the global COVID-19 pandemic made it difficult for the Czech company to focus on bringing a new product to market, to the point that some had begun to wonder if we’d ever see this mythical machine.

But now, finally, the wait is over. Or perhaps, it’s just beginning. That’s because while Prusa Research has officially announced their new XL model and opened preorders for the $1,999+ USD printer, it’s not expected to ship until at least the second quarter of 2022. That’s already a pretty substantial lead time, but given Prusa’s track record when it comes to product launches, we wouldn’t be surprised if early adopters don’t start seeing their machines until this time next year.

So what do you get for your money? Well, not an over-sized Prusa i3, that’s for sure. While many had speculated the XL would simply be a larger version of the company’s popular open source printer with a few modern niceties like a 32-bit control board sprinkled in, the reality is something else entirely. While the high purchase price and ponderous dimensions of the new machine might make it a tough sell for many in the hacker and maker communities, there’s little question that the technical improvements and innovations built into the Prusa XL provide a glimpse of the future for the desktop 3D printer market as a whole.

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Can A 3D Printer Print Better Filament For Itself?

3D printed parts are generally no way near the strength of an equivalent injection moulded part and techniques such as a sustained heat treatment, though effective usually distort the part beyond use.

[CNC Kitchen] was investigating the results (video, embedded below) of a recent paper, that described a novel ABS filament reinforced by a “star” shaped Polycarbonate core, an arrangement the authors claim is resilient to deformation during the annealing process often necessary to increase part strength. While the researchers had access to specialised equipment needed to manufacture such a composite material, [CNC Kitchen’s] solution of simply using his dual extruder setup to directly print the required hybrid filament is something we feel, strongly resonates with the now old school, RepRap “print your printer” sentiment.

The printed filament seems to have reasonable dimensional accuracy and passing the printed spool through a heater block without the nozzle attached, ensured there would be no obvious clogs. The rest of the video focuses on a very thorough comparison of strength and deformation between the garden variety Polycarbonate, ABS and this new hybrid filament after the annealing process. Although he concludes with mixed results, just being able to combine and print your own hybrid filament is super cool and a success in its own right!

Interested in multi-material filaments? Check out our article on a more conventional approach which does not involve printing it yourself!

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Giant 3D Printer For Giant Projects

Established FDM 3D printers designs generally lead themselves well to being scaled up, as long as you keep frame stiffness, alignment and movement in mind. [Ivan Miranda] needed a big printer for his big projects (videos below), so he built his own i3 style printer with a 800 mm × 500 mm usable print bed and about 500 mm vertical print height.

The frame of the new machine is built using 20×20 and 20×40 aluminium V-slot extrusions with some square tubing for reinforcement. To move all the weight, all 3 axes are driven by double NEMA17 steppers, via a DUET3D board with an expansion board for the extra motors. The extruder is the new E3D Hemera with a 0.8 mm nozzle. The print bed is a mirror, on top of the aluminium plate, headed by a large silicone heat pad. The first bed version used a smaller heat pad directly on the back of the mirror, but it heated up unevenly and the mirror ended up cracking. Look out for the ingeniously lightweight and simple cable management to the extruder. When all was said and done he printed a 800 mm long size 66 wrench as a test piece with zero warp, which is pretty good even for PLA. This project is also a perfect example of the power of 3D printing for rapid iterative development, as lot of the printed fittings went through multiple versions.

Although [Ivan] received most of the components for free, a printer like this is still within reach of the rest of us. We look forward to a lot of big prints by [Ivan] in his signature red, like a massive nerf gun and the ridable tank he is currently working on. Continue reading “Giant 3D Printer For Giant Projects”