https://wiki.utopiamaker.com/api.php?action=feedcontributions&feedformat=atom&user=SolumUtopiaMaker's Wiki - User contributions [en]2026-04-30T05:27:56ZUser contributionsMediaWiki 1.32.0https://wiki.utopiamaker.com/index.php?title=Extrusor_de_Pellets_para_Impresi%C3%B3n_3D&diff=1155Extrusor de Pellets para Impresión 3D2019-08-06T17:37:24Z<p>Solum: /* Presentación */</p>
<hr />
<div><br />
[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Extrusor de Pellets]]<br />
[[File:Printer001.jpg|200px|thumb|Impresora con Extrusor de Pellets]]<br />
== Desarrolladores ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:997037 Sebastián Martínez]<br />
<br />
== Presentación ==<br />
<br />
La industria actual de impresión 3D esta siendo limitada a volúmenes inferiores a 30cm3, al pensar en imprimir objetos de gran tamaño el limite principal es el costo del material, si una impresión de un objeto grande utiliza mas de 2 rollos de filamento el método de impresión puede ser descartado por el alto costo, un extrusor de plástico granulado disminuye el costo del material hasta 10 veces y tiene la ventaja adicional de imprimir con boquillas de diámetros superiores a 1mm, lo que aumenta la velocidad de impresión al menos 3 veces comparándola con la impresión de filamento.<br />
<br />
[https://www.youtube.com/watch?v=geIKnWPlsOI&feature=youtu.be Video: FM3D Pellet Extruder ]<br />
<br />
== Recursos ==<br />
Materiales:<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Niple galvanizado para agua de 1/2"(dia) x 3"(long) con doble rosca<br />
*1 X Tapón galvanizado para agua de 1/2"(dia) redondo<br />
*1 X Flanche para piso de 1/2"<br />
*1 X Broca Auger de 1/2" X 5"<br />
*1 X Tubo cuadrado de 70x70mm X70mm (long)<br />
*1 X Motor Nema 23 con caja reductora 1:72 o equivalente<br />
*1 X Acople Rigido de 5mm a 12mm con doble prisionero M3 <br />
*1 X Resistencia tipo abrazadera 12v 90Watts de 28mm(dia) X 30mm(long) <br />
*1 X Termistor EPCOS de 100K<br />
*1 X Cinta Kapton de 30mm ancho<br />
*1 X Cinta de teflon industrial<br />
*2 X Malla metálica 10x10cm<br />
<br />
Herramientas<br />
<br />
Manuales:<br />
<br />
* Destornilladores de pala y estrella<br />
* Alicate<br />
* Llave para tubería<br />
* Llave expansiva<br />
* Llaves allen para tornillos M3 y M6<br />
* Macho para roscar M6<br />
* Broca de 5mm o 3/16" para metal<br />
* Broca de 3mm o 1/8" para metal<br />
<br />
<br />
<br />
Eléctricas:<br />
<br />
* Multimetro<br />
* Taladro<br />
* Pulidora<br />
<br />
== Etapas ==<br />
*1. Construcción del sistema mecánico<br />
*2. Instalación del sistema eléctrico<br />
*3. Pruebas de eficiencia mecánica<br />
*4. Pruebas de eficiencia térmica<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
<br />
=== 1.Construcción del sistema mecánico ===<br />
[[File:115410.jpg|400px|thumb|Ensamble Mecánico]]<br />
Se toman las medidas necesarias para que el ensamble de las piezas permita el desplazamiento del plástico granulado hacia la punta del extrusor donde la temperatura lo transforma en filamento imprimible, se realizan tareas de mecanizado manual sobre el metal para unir los componentes fijos y móviles.<br />
<br />
<gallery><br />
Parts to assemble.jpg|Piezas a ensamblar<br />
Pipe and cap with teflon.jpg|Tuberia y tope con teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Vista superior<br />
Installed.jpg|thumb|Vista inferior<br />
Auger installed.jpg|Broca acoplada al motor<br />
Mechanical assembly.jpg|Vista frontal del ensamble<br />
Mechanical assembly2.jpg|Vista posterior del ensamble<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Instalación del sistema eléctrico ===<br />
Se instala la resistencia, el sensor de temperatura y el cableado del motor, esto se conecta a la tarjeta controladora de la maquina.<br />
<br />
=== 3.Pruebas de eficiencia mecánica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desplazamiento de los pellets en el interiror del extrusor teniendo en cuenta la velocidad y la fuerza necesaria.<br />
<br />
=== 4.Pruebas de eficiencia térmica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desempeño de la resistencia, el control de temperatura y definir la temperatura optima para convertir los pellets en filamento.<br />
<br />
=== 5.Pruebas de fluidez del material ===<br />
Se calienta el extrusor a la temperatura de trabajo antes obtenida y se define la velocidad del motor para generar un hilo continuo de plastico a la mayor velocidad posible, conservando el diámetro y las propiedades del material, en este paso se calculan las longitudes y los tiempos de retracción del material para lograr total control de la extrusión a lo largo de una impresión.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1154Pellet Extruder for 3D Printing2019-08-06T17:27:18Z<p>Solum: /* Introduction */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
[https://www.youtube.com/watch?v=geIKnWPlsOI&feature=youtu.be FM3D Pellet Extruder (In Spanish)]<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
<br />
<gallery><br />
Pipe-1.jpg|Water pipe<br />
Pipe-2.jpg|80px|Water pipe cap<br />
Metal-mesh.jpg|Metal Mesh 10x10cm square<br />
Square structural tube.jpg|Square Structural Tube<br />
Floor-flange.jpg|Floor-flange<br />
<br />
</gallery><br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:115410.jpg|400px|thumb|Mechanical assembly]]<br />
<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
<br />
<gallery><br />
Parts to assemble.jpg|scheme of the pieces to assemble<br />
Pipe and cap with teflon.jpg|Pipe and cap with teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Top View<br />
Installed.jpg|thumb|Bottom View<br />
Auger installed.jpg|Auger Installed<br />
Mechanical assembly.jpg|Mechanical assembly (Front view)<br />
Mechanical assembly2.jpg|Mechanical assembly (Back View)<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1153Pellet Extruder for 3D Printing2019-08-06T17:24:15Z<p>Solum: /* Introduction */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
[https://www.youtube.com/watch?v=geIKnWPlsOI&feature=youtu.be FM3D Pellet Extruder]<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
<br />
<gallery><br />
Pipe-1.jpg|Water pipe<br />
Pipe-2.jpg|80px|Water pipe cap<br />
Metal-mesh.jpg|Metal Mesh 10x10cm square<br />
Square structural tube.jpg|Square Structural Tube<br />
Floor-flange.jpg|Floor-flange<br />
<br />
</gallery><br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:115410.jpg|400px|thumb|Mechanical assembly]]<br />
<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
<br />
<gallery><br />
Parts to assemble.jpg|scheme of the pieces to assemble<br />
Pipe and cap with teflon.jpg|Pipe and cap with teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Top View<br />
Installed.jpg|thumb|Bottom View<br />
Auger installed.jpg|Auger Installed<br />
Mechanical assembly.jpg|Mechanical assembly (Front view)<br />
Mechanical assembly2.jpg|Mechanical assembly (Back View)<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1152Pellet Extruder for 3D Printing2019-08-06T17:23:48Z<p>Solum: /* Introduction */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
[http://<iframe%20width="560"%20height="315"%20src="https://www.youtube.com/embed/geIKnWPlsOI"%20frameborder="0"%20allow="accelerometer;%20autoplay;%20encrypted-media;%20gyroscope;%20picture-in-picture"%20allowfullscreen></iframe> FM3D Pellet Extruder]<br />
<br />
[https://www.youtube.com/watch?v=geIKnWPlsOI&feature=youtu.be FM3D Pellet Extruder]<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
<br />
<gallery><br />
Pipe-1.jpg|Water pipe<br />
Pipe-2.jpg|80px|Water pipe cap<br />
Metal-mesh.jpg|Metal Mesh 10x10cm square<br />
Square structural tube.jpg|Square Structural Tube<br />
Floor-flange.jpg|Floor-flange<br />
<br />
</gallery><br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:115410.jpg|400px|thumb|Mechanical assembly]]<br />
<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
<br />
<gallery><br />
Parts to assemble.jpg|scheme of the pieces to assemble<br />
Pipe and cap with teflon.jpg|Pipe and cap with teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Top View<br />
Installed.jpg|thumb|Bottom View<br />
Auger installed.jpg|Auger Installed<br />
Mechanical assembly.jpg|Mechanical assembly (Front view)<br />
Mechanical assembly2.jpg|Mechanical assembly (Back View)<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Extrusor_de_Pellets_para_Impresi%C3%B3n_3D&diff=1151Extrusor de Pellets para Impresión 3D2019-08-06T17:15:36Z<p>Solum: /* 1.Construcción del sistema mecánico */</p>
<hr />
<div><br />
[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Extrusor de Pellets]]<br />
[[File:Printer001.jpg|200px|thumb|Impresora con Extrusor de Pellets]]<br />
== Desarrolladores ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:997037 Sebastián Martínez]<br />
<br />
== Presentación ==<br />
<br />
La industria actual de impresión 3D esta siendo limitada a volúmenes inferiores a 30cm3, al pensar en imprimir objetos de gran tamaño el limite principal es el costo del material, si una impresión de un objeto grande utiliza mas de 2 rollos de filamento el método de impresión puede ser descartado por el alto costo, un extrusor de plástico granulado disminuye el costo del material hasta 10 veces y tiene la ventaja adicional de imprimir con boquillas de diámetros superiores a 1mm, lo que aumenta la velocidad de impresión al menos 3 veces comparándola con la impresión de filamento.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Recursos ==<br />
Materiales:<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Niple galvanizado para agua de 1/2"(dia) x 3"(long) con doble rosca<br />
*1 X Tapón galvanizado para agua de 1/2"(dia) redondo<br />
*1 X Flanche para piso de 1/2"<br />
*1 X Broca Auger de 1/2" X 5"<br />
*1 X Tubo cuadrado de 70x70mm X70mm (long)<br />
*1 X Motor Nema 23 con caja reductora 1:72 o equivalente<br />
*1 X Acople Rigido de 5mm a 12mm con doble prisionero M3 <br />
*1 X Resistencia tipo abrazadera 12v 90Watts de 28mm(dia) X 30mm(long) <br />
*1 X Termistor EPCOS de 100K<br />
*1 X Cinta Kapton de 30mm ancho<br />
*1 X Cinta de teflon industrial<br />
*2 X Malla metálica 10x10cm<br />
<br />
Herramientas<br />
<br />
Manuales:<br />
<br />
* Destornilladores de pala y estrella<br />
* Alicate<br />
* Llave para tubería<br />
* Llave expansiva<br />
* Llaves allen para tornillos M3 y M6<br />
* Macho para roscar M6<br />
* Broca de 5mm o 3/16" para metal<br />
* Broca de 3mm o 1/8" para metal<br />
<br />
<br />
<br />
Eléctricas:<br />
<br />
* Multimetro<br />
* Taladro<br />
* Pulidora<br />
<br />
== Etapas ==<br />
*1. Construcción del sistema mecánico<br />
*2. Instalación del sistema eléctrico<br />
*3. Pruebas de eficiencia mecánica<br />
*4. Pruebas de eficiencia térmica<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
<br />
=== 1.Construcción del sistema mecánico ===<br />
[[File:115410.jpg|400px|thumb|Ensamble Mecánico]]<br />
Se toman las medidas necesarias para que el ensamble de las piezas permita el desplazamiento del plástico granulado hacia la punta del extrusor donde la temperatura lo transforma en filamento imprimible, se realizan tareas de mecanizado manual sobre el metal para unir los componentes fijos y móviles.<br />
<br />
<gallery><br />
Parts to assemble.jpg|Piezas a ensamblar<br />
Pipe and cap with teflon.jpg|Tuberia y tope con teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Vista superior<br />
Installed.jpg|thumb|Vista inferior<br />
Auger installed.jpg|Broca acoplada al motor<br />
Mechanical assembly.jpg|Vista frontal del ensamble<br />
Mechanical assembly2.jpg|Vista posterior del ensamble<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Instalación del sistema eléctrico ===<br />
Se instala la resistencia, el sensor de temperatura y el cableado del motor, esto se conecta a la tarjeta controladora de la maquina.<br />
<br />
=== 3.Pruebas de eficiencia mecánica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desplazamiento de los pellets en el interiror del extrusor teniendo en cuenta la velocidad y la fuerza necesaria.<br />
<br />
=== 4.Pruebas de eficiencia térmica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desempeño de la resistencia, el control de temperatura y definir la temperatura optima para convertir los pellets en filamento.<br />
<br />
=== 5.Pruebas de fluidez del material ===<br />
Se calienta el extrusor a la temperatura de trabajo antes obtenida y se define la velocidad del motor para generar un hilo continuo de plastico a la mayor velocidad posible, conservando el diámetro y las propiedades del material, en este paso se calculan las longitudes y los tiempos de retracción del material para lograr total control de la extrusión a lo largo de una impresión.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Extrusor_de_Pellets_para_Impresi%C3%B3n_3D&diff=1150Extrusor de Pellets para Impresión 3D2019-08-06T17:14:17Z<p>Solum: /* 1.Construcción del sistema mecánico */</p>
<hr />
<div><br />
[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Extrusor de Pellets]]<br />
[[File:Printer001.jpg|200px|thumb|Impresora con Extrusor de Pellets]]<br />
== Desarrolladores ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:997037 Sebastián Martínez]<br />
<br />
== Presentación ==<br />
<br />
La industria actual de impresión 3D esta siendo limitada a volúmenes inferiores a 30cm3, al pensar en imprimir objetos de gran tamaño el limite principal es el costo del material, si una impresión de un objeto grande utiliza mas de 2 rollos de filamento el método de impresión puede ser descartado por el alto costo, un extrusor de plástico granulado disminuye el costo del material hasta 10 veces y tiene la ventaja adicional de imprimir con boquillas de diámetros superiores a 1mm, lo que aumenta la velocidad de impresión al menos 3 veces comparándola con la impresión de filamento.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Recursos ==<br />
Materiales:<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Niple galvanizado para agua de 1/2"(dia) x 3"(long) con doble rosca<br />
*1 X Tapón galvanizado para agua de 1/2"(dia) redondo<br />
*1 X Flanche para piso de 1/2"<br />
*1 X Broca Auger de 1/2" X 5"<br />
*1 X Tubo cuadrado de 70x70mm X70mm (long)<br />
*1 X Motor Nema 23 con caja reductora 1:72 o equivalente<br />
*1 X Acople Rigido de 5mm a 12mm con doble prisionero M3 <br />
*1 X Resistencia tipo abrazadera 12v 90Watts de 28mm(dia) X 30mm(long) <br />
*1 X Termistor EPCOS de 100K<br />
*1 X Cinta Kapton de 30mm ancho<br />
*1 X Cinta de teflon industrial<br />
*2 X Malla metálica 10x10cm<br />
<br />
Herramientas<br />
<br />
Manuales:<br />
<br />
* Destornilladores de pala y estrella<br />
* Alicate<br />
* Llave para tubería<br />
* Llave expansiva<br />
* Llaves allen para tornillos M3 y M6<br />
* Macho para roscar M6<br />
* Broca de 5mm o 3/16" para metal<br />
* Broca de 3mm o 1/8" para metal<br />
<br />
<br />
<br />
Eléctricas:<br />
<br />
* Multimetro<br />
* Taladro<br />
* Pulidora<br />
<br />
== Etapas ==<br />
*1. Construcción del sistema mecánico<br />
*2. Instalación del sistema eléctrico<br />
*3. Pruebas de eficiencia mecánica<br />
*4. Pruebas de eficiencia térmica<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
<br />
=== 1.Construcción del sistema mecánico ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Se toman las medidas necesarias para que el ensamble de las piezas permita el desplazamiento del plástico granulado hacia la punta del extrusor donde la temperatura lo transforma en filamento imprimible, se realizan tareas de mecanizado manual sobre el metal para unir los componentes fijos y móviles.<br />
<br />
<gallery><br />
Parts to assemble.jpg|Piezas a ensamblar<br />
Pipe and cap with teflon.jpg|Tuberia y tope con teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Vista superior<br />
Installed.jpg|thumb|Vista inferior<br />
Auger installed.jpg|Broca acoplada al motor<br />
Mechanical assembly.jpg|Vista frontal del ensamble<br />
Mechanical assembly2.jpg|Vista posterior del ensamble<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Instalación del sistema eléctrico ===<br />
Se instala la resistencia, el sensor de temperatura y el cableado del motor, esto se conecta a la tarjeta controladora de la maquina.<br />
<br />
=== 3.Pruebas de eficiencia mecánica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desplazamiento de los pellets en el interiror del extrusor teniendo en cuenta la velocidad y la fuerza necesaria.<br />
<br />
=== 4.Pruebas de eficiencia térmica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desempeño de la resistencia, el control de temperatura y definir la temperatura optima para convertir los pellets en filamento.<br />
<br />
=== 5.Pruebas de fluidez del material ===<br />
Se calienta el extrusor a la temperatura de trabajo antes obtenida y se define la velocidad del motor para generar un hilo continuo de plastico a la mayor velocidad posible, conservando el diámetro y las propiedades del material, en este paso se calculan las longitudes y los tiempos de retracción del material para lograr total control de la extrusión a lo largo de una impresión.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1149Pellet Extruder for 3D Printing2019-08-06T17:11:19Z<p>Solum: /* 1.Building the Mechanics */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
<br />
<gallery><br />
Pipe-1.jpg|Water pipe<br />
Pipe-2.jpg|80px|Water pipe cap<br />
Metal-mesh.jpg|Metal Mesh 10x10cm square<br />
Square structural tube.jpg|Square Structural Tube<br />
Floor-flange.jpg|Floor-flange<br />
<br />
</gallery><br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:115410.jpg|400px|thumb|Mechanical assembly]]<br />
<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
<br />
<gallery><br />
Parts to assemble.jpg|scheme of the pieces to assemble<br />
Pipe and cap with teflon.jpg|Pipe and cap with teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Top View<br />
Installed.jpg|thumb|Bottom View<br />
Auger installed.jpg|Auger Installed<br />
Mechanical assembly.jpg|Mechanical assembly (Front view)<br />
Mechanical assembly2.jpg|Mechanical assembly (Back View)<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1148Pellet Extruder for 3D Printing2019-08-06T17:08:48Z<p>Solum: /* 1.Building the Mechanics */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
<br />
<gallery><br />
Pipe-1.jpg|Water pipe<br />
Pipe-2.jpg|80px|Water pipe cap<br />
Metal-mesh.jpg|Metal Mesh 10x10cm square<br />
Square structural tube.jpg|Square Structural Tube<br />
Floor-flange.jpg|Floor-flange<br />
<br />
</gallery><br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
115410.jpg|400px|Mechanical assembly<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
<br />
<gallery><br />
Parts to assemble.jpg|scheme of the pieces to assemble<br />
Pipe and cap with teflon.jpg|Pipe and cap with teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Top View<br />
Installed.jpg|thumb|Bottom View<br />
Auger installed.jpg|Auger Installed<br />
Mechanical assembly.jpg|Mechanical assembly (Front view)<br />
Mechanical assembly2.jpg|Mechanical assembly (Back View)<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:115410.jpg&diff=1147File:115410.jpg2019-08-06T17:08:18Z<p>Solum: </p>
<hr />
<div>Mechanical assembly</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1146Pellet Extruder for 3D Printing2019-08-06T16:57:24Z<p>Solum: /* 1.Building the Mechanics */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
<br />
<gallery><br />
Pipe-1.jpg|Water pipe<br />
Pipe-2.jpg|80px|Water pipe cap<br />
Metal-mesh.jpg|Metal Mesh 10x10cm square<br />
Square structural tube.jpg|Square Structural Tube<br />
Floor-flange.jpg|Floor-flange<br />
<br />
</gallery><br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
<br />
<gallery><br />
Parts to assemble.jpg|scheme of the pieces to assemble<br />
Pipe and cap with teflon.jpg|Pipe and cap with teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Top View<br />
Installed.jpg|thumb|Bottom View<br />
Auger installed.jpg|Auger Installed<br />
Mechanical assembly.jpg|Mechanical assembly (Front view)<br />
Mechanical assembly2.jpg|Mechanical assembly (Back View)<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1145Pellet Extruder for 3D Printing2019-08-06T16:51:57Z<p>Solum: /* 1.Building the Mechanics */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
<br />
<gallery><br />
Pipe-1.jpg|Water pipe<br />
Pipe-2.jpg|80px|Water pipe cap<br />
Metal-mesh.jpg|Metal Mesh 10x10cm square<br />
Square structural tube.jpg|Square Structural Tube<br />
Floor-flange.jpg|Floor-flange<br />
<br />
</gallery><br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
--------------------//----------------------------------------//--------------------------------------------//----------------------------------------//-------------------------------//---<br />
<gallery><br />
Parts to assemble.jpg|scheme of the pieces to assemble<br />
Pipe and cap with teflon.jpg|Pipe and cap with teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Top View<br />
Installed.jpg|thumb|Bottom View<br />
Auger installed.jpg|Auger Installed<br />
Mechanical assembly.jpg|Mechanical assembly (Front view)<br />
Mechanical assembly2.jpg|Mechanical assembly (Back View)<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Mechanical_assembly2.jpg&diff=1144File:Mechanical assembly2.jpg2019-08-06T16:50:27Z<p>Solum: </p>
<hr />
<div>mechanical assembly</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Mechanical_assembly.jpg&diff=1143File:Mechanical assembly.jpg2019-08-06T16:49:36Z<p>Solum: </p>
<hr />
<div>mechanical assembly</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Auger_installed.jpg&diff=1142File:Auger installed.jpg2019-08-06T16:48:11Z<p>Solum: </p>
<hr />
<div> Auger</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1141Pellet Extruder for 3D Printing2019-08-06T16:41:09Z<p>Solum: /* 1.Building the Mechanics */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
<br />
<gallery><br />
Pipe-1.jpg|Water pipe<br />
Pipe-2.jpg|80px|Water pipe cap<br />
Metal-mesh.jpg|Metal Mesh 10x10cm square<br />
Square structural tube.jpg|Square Structural Tube<br />
Floor-flange.jpg|Floor-flange<br />
<br />
</gallery><br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
--------------------//----------------------------------------//--------------------------------------------//----------------------------------------//-------------------------------//---<br />
<gallery><br />
Parts to assemble.jpg|scheme of the pieces to assemble<br />
Pipe and cap with teflon.jpg|Pipe and cap with teflon<br />
Floor flange installed.jpg|Floor Flange installed<br />
Base sheet installed.jpg|Top View<br />
Installed.jpg|thumb|Bottom View<br />
<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Installed.jpg&diff=1140File:Installed.jpg2019-08-06T16:40:26Z<p>Solum: </p>
<hr />
<div>installed</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Base_sheet_installed.jpg&diff=1139File:Base sheet installed.jpg2019-08-06T16:39:03Z<p>Solum: </p>
<hr />
<div>installed</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Floor_flange_installed.jpg&diff=1138File:Floor flange installed.jpg2019-08-06T16:37:34Z<p>Solum: </p>
<hr />
<div>Floor Flange installed</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Pipe_and_cap_with_teflon.jpg&diff=1137File:Pipe and cap with teflon.jpg2019-08-06T16:35:57Z<p>Solum: </p>
<hr />
<div>pipe and cap with teflon</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1136Pellet Extruder for 3D Printing2019-08-06T16:33:57Z<p>Solum: /* Bill of Materials */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
<br />
<gallery><br />
Pipe-1.jpg|Water pipe<br />
Pipe-2.jpg|80px|Water pipe cap<br />
Metal-mesh.jpg|Metal Mesh 10x10cm square<br />
Square structural tube.jpg|Square Structural Tube<br />
Floor-flange.jpg|Floor-flange<br />
<br />
</gallery><br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
--------------------//----------------------------------------//--------------------------------------------//----------------------------------------//-------------------------------//---<br />
<gallery><br />
Parts to assemble.jpg|7<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1135Pellet Extruder for 3D Printing2019-08-06T16:29:47Z<p>Solum: /* Stages */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
--------------------//----------------------------------------//--------------------------------------------//----------------------------------------//-------------------------------//---<br />
<gallery><br />
Parts to assemble.jpg|7<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1134Pellet Extruder for 3D Printing2019-08-06T16:28:50Z<p>Solum: /* 1.Building the Mechanics */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
--------------------//----------------------------------------//--------------------------------------------//----------------------------------------//-------------------------------//---<br />
<gallery><br />
Pipe-1.jpg|1<br />
Pipe-2.jpg|80px|2<br />
Metal-mesh.jpg|3<br />
Square structural tube.jpg|4<br />
Floor-flange.jpg|5<br />
Plate.jpg|6<br />
Parts to assemble.jpg7<br />
<br />
</gallery><br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Parts_to_assemble.jpg&diff=1133File:Parts to assemble.jpg2019-08-06T16:28:26Z<p>Solum: </p>
<hr />
<div>parts to assemble</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Plate.jpg&diff=1132File:Plate.jpg2019-08-06T16:23:09Z<p>Solum: </p>
<hr />
<div>plate</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Floor-flange.jpg&diff=1131File:Floor-flange.jpg2019-08-06T16:18:49Z<p>Solum: </p>
<hr />
<div>floor flange</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1130Pellet Extruder for 3D Printing2019-08-06T16:11:50Z<p>Solum: /* 1.Building the Mechanics */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
--------------------//----------------------------------------//--------------------------------------------//----------------------------------------//-------------------------------//---<br />
[[File:Pipe-1.jpg|80px|thumb]]<br />
[[File:Pipe-2.jpg|80px|thumb]]<br />
[[File:Metal-mesh.jpg|80px|thumb]]<br />
[[File:Square structural tube.jpg|80px|thumb]]<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1129Pellet Extruder for 3D Printing2019-08-06T16:10:12Z<p>Solum: /* 1.Building the Mechanics */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Developmen team ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
* [https://es.utopiamaker.com/m3duto/user:993037 Sebastián Martínez]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due to the cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
--------------------//----------------------------------------//--------------------------------------------//----------------------------------------//-------------------------------//---<br />
[[File:Pipe-1.jpg|400px|thumb]]<br />
[[File:Pipe-2.jpg|400px|thumb]]<br />
[[File:Metal-mesh.jpg|400px|thumb]]<br />
[[File:Square structural tube.jpg|400px|thumb]]<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify the correct movement of the pellets inside of the extruder, verify the speed and strength requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verify the heating element performance and define the optimal temperature to melt the plastic and make it flow through the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperature and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine at different tempetatures, speeds, accelerations and retraction rates, make some test to adjust the settings for different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor of 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustments and some tests, the extruder presented a better speed and acceleration control, and an improved print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until now we have achieved good performance on the Pellet Extruder using PLA pellets, which reduce the printing cost ten times compared with filament printing method.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x10 mm groove. this one has a moving part that controls the material output at different times of the print. The operation principle is the same that an industrial type plastic sheet extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm wide and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements it closes completely to avoid unwanted extrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm, it was built using recycled materials, a whiskey box for the extruder and motors extracted from a paper printer, we use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with gearbox has been installed on the tip of the extruder, which moves a rod along a groove with 10 mm wide and 1 mm diameter, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Square_structural_tube.jpg&diff=1128File:Square structural tube.jpg2019-08-06T16:09:36Z<p>Solum: </p>
<hr />
<div>Square tube</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Metal-mesh.jpg&diff=1127File:Metal-mesh.jpg2019-08-06T16:08:28Z<p>Solum: </p>
<hr />
<div>metal mesh</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Pipe-2.jpg&diff=1126File:Pipe-2.jpg2019-08-06T16:06:13Z<p>Solum: </p>
<hr />
<div>Pipe cap</div>Solumhttps://wiki.utopiamaker.com/index.php?title=File:Pipe-1.jpg&diff=1125File:Pipe-1.jpg2019-08-06T16:04:15Z<p>Solum: </p>
<hr />
<div>Cutted Pipe</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1085Pellet Extruder for 3D Printing2019-07-31T17:19:32Z<p>Solum: /* Estado del Proyecto */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verifythe heating elemente performance and define the optimal temperature to melt the plastic and make it flow though the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperaute and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine in different tempetature, speed, work acceleration and retraction, make some test to adjust the settings in different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor with 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustements and some tests, the extruder presented a better speed and acceleration development, and a better print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until this moment we have achieved the right development of the Pellet Extruder using PLA pellets, which reduce the prinitng cost to one tenth in comparison with filament printing methood.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x1 cm groove. this one has a moving part that controlls the material output in different times of the print. The operation principle is the same that an Industrial Type Plastic sheet Extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements, it closes completely to avoid unwanted intrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm and we build it with recycled material from the furniture, a whiskey box for the extruder, an engine extracted from a printer, We use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with reducer has been installed on the tip of the extruder, which moves a lace along a groove with 10 mm wide and 1 mm thick, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Project Status ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
* We designed the parts for the printer, to eplace the temporal parts, the machine will create this pieces in the second week of June<br />
<br />
20/05/2019<br />
*We are making simulation on Rhinoceros Grsshopper, for the Gcode generation.<br />
*Post process tests have been done in Slic3r with Perl Language for the Gcode generation.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.<br />
<br />
24/06/2019<br />
*A temporal Method to generate Gcode for the Machine with CNC software and manual edition for Gcode archives has been found.<br />
*A professional with knowledge in mathematics and programing is required for generate the codes that will make the extruder work properly.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1084Pellet Extruder for 3D Printing2019-07-31T16:59:51Z<p>Solum: /* Avances Adicionales */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verifythe heating elemente performance and define the optimal temperature to melt the plastic and make it flow though the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperaute and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine in different tempetature, speed, work acceleration and retraction, make some test to adjust the settings in different models.<br />
<br />
== Additional advance ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor with 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustements and some tests, the extruder presented a better speed and acceleration development, and a better print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until this moment we have achieved the right development of the Pellet Extruder using PLA pellets, which reduce the prinitng cost to one tenth in comparison with filament printing methood.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x1 cm groove. this one has a moving part that controlls the material output in different times of the print. The operation principle is the same that an Industrial Type Plastic sheet Extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements, it closes completely to avoid unwanted intrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm and we build it with recycled material from the furniture, a whiskey box for the extruder, an engine extracted from a printer, We use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with reducer has been installed on the tip of the extruder, which moves a lace along a groove with 10 mm wide and 1 mm thick, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1083Pellet Extruder for 3D Printing2019-07-31T16:58:23Z<p>Solum: /* Avances Adicionales */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verifythe heating elemente performance and define the optimal temperature to melt the plastic and make it flow though the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperaute and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine in different tempetature, speed, work acceleration and retraction, make some test to adjust the settings in different models.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor with 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustements and some tests, the extruder presented a better speed and acceleration development, and a better print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until this moment we have achieved the right development of the Pellet Extruder using PLA pellets, which reduce the prinitng cost to one tenth in comparison with filament printing methood.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x1 cm groove. this one has a moving part that controlls the material output in different times of the print. The operation principle is the same that an Industrial Type Plastic sheet Extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements, it closes completely to avoid unwanted intrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*We have built a second printer that we will use exclusively for the development of the sheet extruder, it has a print volume of 300x400x300 mm and we build it with recycled material from the furniture, a whiskey box for the extruder, an engine extracted from a printer, We use beer cans and resistive material from an old toaster for the heating element of the extruder.<br />
<br />
A stepper motor with reducer has been installed on the tip of the extruder, which moves a lace along a groove with 10 mm wide and 1 mm thick, this mechanism has been built entirely by hand with the help of a motortool and a manual drill.<br />
<br />
<gallery><br />
Machine front.jpg|Sheet Printer front<br />
Machine back.jpg|Sheet Printer Back<br />
Extrusor_laminar_001.jpg|Nozzle´s side<br />
Mech top.jpg|Nozzle's top<br />
Extrusor_laminar_003.jpg|Installed Nozzle<br />
Extrusor_laminar_005.jpg|Installed Nozzle<br />
Boquilla cerrada.png|Closed Nozzle<br />
Boquilla medio.png|50% Nozzle<br />
Boquilla abierta.png|Open nozzle<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1082Pellet Extruder for 3D Printing2019-07-31T16:24:06Z<p>Solum: /* Avances Adicionales */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verifythe heating elemente performance and define the optimal temperature to melt the plastic and make it flow though the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperaute and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine in different tempetature, speed, work acceleration and retraction, make some test to adjust the settings in different models.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor with 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustements and some tests, the extruder presented a better speed and acceleration development, and a better print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
*We take as a fact that a big volume print is expensive and take a long time, until this moment we have achieved the right development of the Pellet Extruder using PLA pellets, which reduce the prinitng cost to one tenth in comparison with filament printing methood.<br />
<br />
To solve the printing time problem a variable volume printing nozzle has been designed, it's a extrusion tip that doesn't have a specific diameter orifice, it has a 1x1 cm groove. this one has a moving part that controlls the material output in different times of the print. The operation principle is the same that an Industrial Type Plastic sheet Extruder has, but simplified to be installed in a moving shafts system.<br />
The action strategy of this printing Tip is that when it is making outer perimeters the nozzle closes to let out a 1x1mm filament, that's how we can make the outer layers with good level of detailing, in the moment of filling the piece it opens up to 10mm and performs the work at least 6 times faster than a conventional extruder and when it is executing the displacements, it closes completely to avoid unwanted intrusions before reaching the work coordinates.<br />
<br />
<gallery><br />
imp00.jpg|Nozzle close<br />
imp11.jpg|Opening for Perimeter<br />
imp22.jpg|Opening for Filling<br />
nozzleseq1.png|Opening for Perimeter<br />
nozzleseq2.png|50% Opening<br />
nozzleseq3.png|75% Opening<br />
nozzleseq5.png|100% Opening<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1066Pellet Extruder for 3D Printing2019-07-29T18:07:24Z<p>Solum: /* Avances Adicionales */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verifythe heating elemente performance and define the optimal temperature to melt the plastic and make it flow though the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperaute and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine in different tempetature, speed, work acceleration and retraction, make some test to adjust the settings in different models.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor with 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustements and some tests, the extruder presented a better speed and acceleration development, and a better print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Print test<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
<br />
We take as a fact that a big volume print is expensive and take a long time.<br />
<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1065Pellet Extruder for 3D Printing2019-07-29T16:30:49Z<p>Solum: /* Avances Adicionales */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verifythe heating elemente performance and define the optimal temperature to melt the plastic and make it flow though the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperaute and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine in different tempetature, speed, work acceleration and retraction, make some test to adjust the settings in different models.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Since the first assembly of the extruder, we used a Nema 17 motor with 2,2kg/cm Torque and 1:50 gearbox, which presented printing failures and loss of steps due to overheating, which also affected printing speed, something visible in the quality of the printed pieces, to solve this problem the motor has been replaced with a Nema 23 with 9 kg/cm torque and 1:72 gearbox, after the software adjustements and some tests, the extruder presented a better speed and acceleration development, and a better print quality.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extruder with Nema motor 17 1:50<br />
Motorupgrade02.jpg|Extruder with Nema motor 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Piece Side View<br />
Muestrapiezapelletsmotorupgrade02.jpg|Piece Up View<br />
Motorupgrade.jpg|Print Test<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1051Pellet Extruder for 3D Printing2019-07-25T17:58:24Z<p>Solum: /* 6.Integración a la impresora 3D */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verifythe heating elemente performance and define the optimal temperature to melt the plastic and make it flow though the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.3D Printer integration ===<br />
Use the temperaute and displacement data to adjust the printer firmware parameters, this will be integrated to the machine and will always work as a normal extruder, the data will be used too in the software "slic3r" to generate G codes for the machine in different tempetature, speed, work acceleration and retraction, make some test to adjust the settings in different models.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1050Pellet Extruder for 3D Printing2019-07-25T17:32:44Z<p>Solum: /* 5.Pruebas de fluidez del material */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verifythe heating elemente performance and define the optimal temperature to melt the plastic and make it flow though the tube.<br />
<br />
=== 5.Material flow test ===<br />
Heat the extruder to the work temperature obtained before, and define the motor's speed to produce a continuos string of plastic as fast as possible, maintaining the diameter and the material properties. In this step the lenght and material's retraction time are calculated, to get total control of the extrusion during an impression.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1049Pellet Extruder for 3D Printing2019-07-25T17:12:44Z<p>Solum: /* 4.Pruebas de eficiencia térmica */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Thermal efficiency test ===<br />
From the computer, send commands to the controller board to verifythe heating elemente performance and define the optimal temperature to melt the plastic and make it flow though the tube.<br />
<br />
=== 5.Pruebas de fluidez del material ===<br />
Se calienta el extrusor a la temperatura de trabajo antes obtenida y se define la velocidad del motor para generar un hilo continuo de plastico a la mayor velocidad posible, conservando el diámetro y las propiedades del material, en este paso se calculan las longitudes y los tiempos de retracción del material para lograr total control de la extrusión a lo largo de una impresión.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1048Pellet Extruder for 3D Printing2019-07-25T17:05:53Z<p>Solum: /* 3.Pruebas de eficiencia mecánica */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Mechanical efficiency test ===<br />
From the computer, send commands to the controller board to verify th correct movemente of the pellets inside of the extruder, verify the speed and strengh requirements.<br />
<br />
=== 4.Pruebas de eficiencia térmica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desempeño de la resistencia, el control de temperatura y definir la temperatura optima para convertir los pellets en filamento.<br />
<br />
=== 5.Pruebas de fluidez del material ===<br />
Se calienta el extrusor a la temperatura de trabajo antes obtenida y se define la velocidad del motor para generar un hilo continuo de plastico a la mayor velocidad posible, conservando el diámetro y las propiedades del material, en este paso se calculan las longitudes y los tiempos de retracción del material para lograr total control de la extrusión a lo largo de una impresión.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1047Pellet Extruder for 3D Printing2019-07-25T17:03:44Z<p>Solum: /* 2.Instalación del sistema eléctrico */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Installing the electrical system ===<br />
Install the heating element, the heat sensor and motor wiring, this is connected to the machine's controller board.<br />
<br />
=== 3.Pruebas de eficiencia mecánica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desplazamiento de los pellets en el interior del extrusor teniendo en cuenta la velocidad y la fuerza necesaria.<br />
<br />
=== 4.Pruebas de eficiencia térmica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desempeño de la resistencia, el control de temperatura y definir la temperatura optima para convertir los pellets en filamento.<br />
<br />
=== 5.Pruebas de fluidez del material ===<br />
Se calienta el extrusor a la temperatura de trabajo antes obtenida y se define la velocidad del motor para generar un hilo continuo de plastico a la mayor velocidad posible, conservando el diámetro y las propiedades del material, en este paso se calculan las longitudes y los tiempos de retracción del material para lograr total control de la extrusión a lo largo de una impresión.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1046Pellet Extruder for 3D Printing2019-07-25T16:55:35Z<p>Solum: /* Stages */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Thermal Efficiency Test<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Instalación del sistema eléctrico ===<br />
Se instala la resistencia, el sensor de temperatura y el cableado del motor, esto se conecta a la tarjeta controladora de la maquina.<br />
<br />
=== 3.Pruebas de eficiencia mecánica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desplazamiento de los pellets en el interior del extrusor teniendo en cuenta la velocidad y la fuerza necesaria.<br />
<br />
=== 4.Pruebas de eficiencia térmica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desempeño de la resistencia, el control de temperatura y definir la temperatura optima para convertir los pellets en filamento.<br />
<br />
=== 5.Pruebas de fluidez del material ===<br />
Se calienta el extrusor a la temperatura de trabajo antes obtenida y se define la velocidad del motor para generar un hilo continuo de plastico a la mayor velocidad posible, conservando el diámetro y las propiedades del material, en este paso se calculan las longitudes y los tiempos de retracción del material para lograr total control de la extrusión a lo largo de una impresión.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1045Pellet Extruder for 3D Printing2019-07-25T16:49:22Z<p>Solum: /* Stages */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Installing the Electrical system<br />
*3. Mechanic Efficiency Test<br />
*4. Termic Efficiency Teste<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Instalación del sistema eléctrico ===<br />
Se instala la resistencia, el sensor de temperatura y el cableado del motor, esto se conecta a la tarjeta controladora de la maquina.<br />
<br />
=== 3.Pruebas de eficiencia mecánica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desplazamiento de los pellets en el interior del extrusor teniendo en cuenta la velocidad y la fuerza necesaria.<br />
<br />
=== 4.Pruebas de eficiencia térmica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desempeño de la resistencia, el control de temperatura y definir la temperatura optima para convertir los pellets en filamento.<br />
<br />
=== 5.Pruebas de fluidez del material ===<br />
Se calienta el extrusor a la temperatura de trabajo antes obtenida y se define la velocidad del motor para generar un hilo continuo de plastico a la mayor velocidad posible, conservando el diámetro y las propiedades del material, en este paso se calculan las longitudes y los tiempos de retracción del material para lograr total control de la extrusión a lo largo de una impresión.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solumhttps://wiki.utopiamaker.com/index.php?title=Pellet_Extruder_for_3D_Printing&diff=1044Pellet Extruder for 3D Printing2019-07-25T16:00:10Z<p>Solum: /* 3.Pruebas de eficiencia mecánica */</p>
<hr />
<div>[[category:project]]<br />
[[File:Motorupgrade03.jpg|200px|thumb|Pellet Extruder]]<br />
[[File:Printer001.jpg|200px|thumb|Pellet 3D Printer]]<br />
== Project Manager ==<br />
* [https://es.utopiamaker.com/m3duto/user:197823 Fabian Bustos Quijano]<br />
<br />
== Introduction ==<br />
<br />
The current 3D printing industry is being limited to volumes less than 30cm3, when thinking about printing large objects the major limit is the cost of the material, if a printing session of a large object uses more than 2 rolls of filament the printing method can be discarded due the high cost, a granulated plastic extruder decreases the cost of the material up to 10 times and has the additional advantage of printing with nozzles with diameters greater than 1mm, which increases the printing speed at least 3 times compared to the Filament printing, other great advantage of this method is the opportunity to put additives, colorants and chips of other materials like carbon fiber which generates strong printed parts of composite materials.<br />
<br />
_____________________________________https://youtu.be/geIKnWPlsOI___________________________________<br />
<br />
== Bill of Materials ==<br />
<br />
[[File:Materiales.png|500px|thumb|Materiales]]<br />
*1 X Water pipe Nipple 1/2"(dia) x 3"(long) double thread, Iron or Copper<br />
*1 X Water pipe cap 1/2"(dia) round, Iron or Copper<br />
*1 X Floor Flange Fitting 1/2" thread, Iron or Copper<br />
*1 X Auger bit 1/2"(dia) X 5" <br />
*1 X Square structural tube 70mm x 70mm X 70mm (long), Iron<br />
*1 X Nema 23 Stepper Motor with 1:72 Gearbox<br />
*1 X Rigid Coupling 5mm to 12mm (for bit and motor shafts) <br />
*1 X Band Resistive Heater 12v 90Watts 28mm(dia) X 30mm(long) <br />
*1 X Thermistor EPCOS 100K<br />
*1 X Kapton Tape de 30mm width<br />
*1 X Teflon Tape<br />
*2 X Metal Mesh Square 10x10cm <br />
<br />
Manual Tools:<br />
<br />
* Slot and Philips Screwdrivers<br />
* Pliers<br />
* Pipe Wrench<br />
* Slim-Jaw Adjustable Wrench<br />
* Allen Key Set<br />
* Thread Tap M6<br />
<br />
<br />
Electric Tools:<br />
<br />
* Multimeter<br />
* Drill <br />
-Drill Bits<br />
-1" Saw Cup for Metal<br />
* Angle Grinder<br />
<br />
== Stages ==<br />
*0. Disclaimer<br />
*1. Building the Mechanics<br />
*2. Instalación del sistema eléctrico<br />
*3. Pruebas de eficiencia mecánica<br />
*4. Pruebas de eficiencia térmica<br />
*5. Pruebas de fluidez del material<br />
*6. Integración a la impresora 3D<br />
<br />
=== 0.Disclaimer ===<br />
This is a Technical Tutorial for the construction of an Industrial Grade Device which means that only qualified and experienced personnel could execute and obtain the appropiate result without damage, if you dont feel in the capacity to perform the tasks I show in the next steps, dont worry, just find the appropiate place, the appropiate person and the appropiate tools to get it done, keep in mind that the most important thing is your integrity and this is not intended as a manual to harm yourself in the process, be careful with the instructions, try to make this work in a good mood and mind clear of alcohol or any other product that could affect your performance, I dont take any responsibility of the use of this information.<br />
<br />
=== 1.Building the Mechanics ===<br />
[[File:ensamble.jpg|400px|thumb|Ensamble Mecánico]]<br />
Before we start there is something that we have to understand, is the fact that we are dealing with high density thermoplastics, those materials need high temperatures and lots of force to manipulate, it means that all the mechanics we are going to build here will be made out of metal, because of this, hard work with "heavy tools" are needed, the material I've succesfully used is iron due to their ideal heath transfer properties for this project, avoid of use alluminum, if it is a problem for you to find iron parts you can use bronze instead which has been proven to give good result.<br />
<br />
1.1 Cut 70mm of structural square tube of 70mm by 70mm, you can use the angle grinder with metal cutting disc, this cube will serve as container and the chassis of the extruder.<br />
<br />
1.2 Use the Drill with the 1"Saw Cup to make two holes perfectly aligned at the center of the cube.<br />
<br />
1.3 Place and center the flange in one hole, mark down the points where the screws will be placed, Place the motor on the other hole, carefully center the axle on the hole and mark down the points where the screws will support the motor.<br />
<br />
1.4<br />
<br />
=== 2.Instalación del sistema eléctrico ===<br />
Se instala la resistencia, el sensor de temperatura y el cableado del motor, esto se conecta a la tarjeta controladora de la maquina.<br />
<br />
=== 3.Pruebas de eficiencia mecánica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desplazamiento de los pellets en el interior del extrusor teniendo en cuenta la velocidad y la fuerza necesaria.<br />
<br />
=== 4.Pruebas de eficiencia térmica ===<br />
Se envían comandos a la tarjeta controladora desde el computador para verificar el correcto desempeño de la resistencia, el control de temperatura y definir la temperatura optima para convertir los pellets en filamento.<br />
<br />
=== 5.Pruebas de fluidez del material ===<br />
Se calienta el extrusor a la temperatura de trabajo antes obtenida y se define la velocidad del motor para generar un hilo continuo de plastico a la mayor velocidad posible, conservando el diámetro y las propiedades del material, en este paso se calculan las longitudes y los tiempos de retracción del material para lograr total control de la extrusión a lo largo de una impresión.<br />
<br />
=== 6.Integración a la impresora 3D ===<br />
Se toman los datos de temperatura y de movimiento para ajustar el firmware de la impresora, estos quedaran integrados a la maquina y se usaran siempre como un extrusor normal, los datos también se usan en el software slic3r para generar los códigos G especialmente para la maquina, a las temperaturas, velocidades, aceleraciones de trabajo y retracción, se hacen varias impresiones para acomodar las configuraciones en diferentes tipos de piezas.<br />
<br />
== Avances Adicionales ==<br />
10/06/2019<br />
*<br />
Desde el primer ensamble del extrusor se ha utilizado un motor Nema 17 de 2,2kg/cm de torque con caja reductora de relación 1:50, el cual ha presentado fallas en plena impresión como perdida de pasos debido al calentamiento del mismo, lo que tambien afecta la velocidad, esto se ve reflejado en el acabado y la calidad de las piezas impresas, para solucionar este problema se ha reemplazado el motor por un Nema 23 de 9kg/cm de torque con caja reductora de relación 1:72, despues de los ajustes de software y algunas pruebas, el extrusor presenta un desempeño superior en velocidad, aceleración y por ende la calidad de las impresiones es óptima.<br />
<br />
<gallery><br />
Oldmotor.jpg|Extrusor con motor Nema 17 1:50<br />
Motorupgrade02.jpg|Extrusor con motor Nema 23 1:72<br />
Muestrapiezapelletsmotorupgrade.jpg|Pieza vista lateral<br />
Muestrapiezapelletsmotorupgrade02.jpg|Pieza vista superior<br />
Motorupgrade.jpg|Impresion de prueba<br />
letraKpelletsavisoutopia.jpg|Impresion de prueba<br />
<br />
</gallery><br />
<br />
23/05/2019<br />
*Se toma como base el hecho de que una impresión de gran volumen tiene un costo elevado y toma mucho tiempo, lo que se ha logrado hasta el momento es hacer funcionar el extrusor de manera optima usando pellets de PLA lo que reduce el costo de impresión a una décima parte comparando este con el metodo de impresion con filamento.<br />
<br />
Para solucionar el problema del tiempo de impresión se ha diseñado una boquilla de impresión de volumen variable, se trata de una punta de extrusion que en lugar de un orificio de diametro fijo tiene una ranura de 1cm de largo por 1mm de ancho, esta ranura tiene una pieza movil que controla la salida de material en diferentes momentos de una impresión, el principio de funcionamiento es igual al de una extrusora de lamina plasica tipo industrial pero simplificada para ser instalada en un sistema de ejes moviles, la estrategia de acción de esta punta de impresión es que al momento de hacer perimetros exteriores la boquilla se cierra dejando salir un filamento de 1x1mm, asi puede hacer las capas exteriores con buen nivel de detalle, al momento de hacer el relleno de la pieza esta se abre hasta 10mm y realiza el trabajo al menos 6 veces mas rapido que una extrusor convencional, al ejecutar los desplazamientos se cierra totalmente para evitar extrusiones no deseadas antes de llegar a las coordenadas de trabajo.<br />
<br />
<gallery><br />
imp00.jpg|Boquilla Cerrada<br />
imp11.jpg|Apertura para Perimetros<br />
imp22.jpg|Apertura para Relleno<br />
nozzleseq1.png|Apertura para Perimetros<br />
nozzleseq2.png|Apertura 50% <br />
nozzleseq3.png|Apertura 75%<br />
nozzleseq5.png|Apertura 100%<br />
</gallery><br />
<br />
24/06/2019<br />
<br />
*Se ha construido una segunda impresora que se usara exclusivamente para el desarrollo del extrusor laminar, esta tiene un volumen de impresion de 300X400x300mm y se ha construido con materiales reciclados de muebles, una caja de whiskey para el extrusor, motores extraidos de una fotocopiadora, se usaron latas de cerveza y material resistivo extraido de una tostadora vieja para el elemento calentador del extrusor.<br />
<br />
En la punta del extrusor se ha instalado un motor paso a paso con reductor, el cual mueve una puntilla a lo largo de una ranura de 10mm de ancho y 1mm de grosor, este mecanismo se ha construido totalmente a mano con la ayuda de un motortool y un taladro manual.<br />
<br />
<gallery><br />
Machine front.jpg|Impresora Laminar Frente<br />
Machine back.jpg|Impresora Laminar Atras<br />
Extrusor_laminar_001.jpg|Boquilla lateral<br />
Mech top.jpg|Boquilla Superior<br />
Extrusor_laminar_003.jpg|Boquilla Instalada<br />
Extrusor_laminar_005.jpg|Boquilla Instalada<br />
Boquilla cerrada.png|Boquilla Cerrada<br />
Boquilla medio.png|Boquilla al 50%<br />
Boquilla abierta.png|Boquilla Abierta<br />
</gallery><br />
<br />
== Estado del Proyecto ==<br />
10/06/2019 [[File:Piezas pellet printer.jpg|300px|thumb|Piezas Pellet Printer]]<br />
*Se han diseñado las piezas de la impresora, para reemplazar las provisionales de madera, la maquina creara estas piezas la 2da semana de Junio<br />
<br />
20/05/2019<br />
*Se estan haciendo simulaciones en Grasshopper de Rhinoceros para la generación del Gcode.<br />
*Se han hecho pruebas de postproceso con lenguaje Perl en Slic3r para generación de Gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente<br />
<br />
24/06/2019<br />
*Se ha encontrado un metodo temporal de generar gcode para pruebas de la maquina con software CNC y un poco de edicion manual de los archivos gcode.<br />
*Se necesita de un profesional con conocimiento en matematicas y programación para generar los codigos que haran funcionar el extrusor correctamente.</div>Solum