Published:
October 12, 2021
Category:
Design / Ideas
Client:
FEGO Electric Power
3D Extruder Machine
What is even a filament Extuder?
Filament extruders are truly amazing machines that hold significant importance in the fascinating world of 3D printing. Just take a moment to imagine the incredible power of being able to change plastic pellets, which are small bits of plastic, into high-quality plastic wires. These wires are usually called filaments and they are used as the main printing material in 3D printers. This is exactly the primary function of a filament extruder. To help visualize this, you can think of it as being similar to an ink cartridge found in a conventional printer. The filaments produced by these extruders are what bring your creative ideas and designs to life, allowing you to create three-dimensional objects right in front of you.
At 1010 Industries, our team has the exciting responsibility of developing an innovative, functioning, and strong design that can operate continuously for several hours without interruption. We are utilizing readily available components that are commonly found on the market. A key focus of our design process is making sure that the machine is robust, meaning it can withstand use over time, and is also relatively easy to repair when needed.
This particular project holds a special place for us because we have been actively involved in the 3D printing industry for many years. Historically, we have relied on aftermarket products for our filament needs, which has served us well. However, we were especially eager to create our own filament extruder design, as having this capability in our toolkit would open up many new possibilities for us.
In response to our client’s request, we began by searching for the best electric motor that would provide sufficient torque, which is the power needed to rotate and move the components. We wanted a motor that would be easy for our client to find in their location and simple to replace if necessary. After conducting thorough research, we decided to use a DC motor sourced from a treadmill. This type of motor was chosen due to its ability to meet all of our specifications and ensure ease of replacement for the client.
Moreover, thanks to our modular final design, this motor can be substituted with nearly any motor of an appropriate size. This flexibility is made possible by selecting the right bearings, which are essential for the machine’s performance and adaptability. By focusing on these critical elements, we aim to create a filament extruder that is not only effective in producing high-quality filaments but also user-friendly and convenient for our clients.
“3D printing will massively reduce the cost of certain products as the cost of labor is removed.”
– Peter Diamandis
Process & Results
The image above shows the first version of our design. Initially, the system was powered by a car wiper motor instead of the treadmill DC motor that we later implemented. This version included a 5/6 14mm feeding screw rod, a barrel measuring 14.5 meters in length, and a nozzle cap with a diameter of 1.2 meters. This initial design was put together quickly to give us a rough idea of how the system could function. However, we realized that many important factors needed consideration before transitioning to later versions aimed at improving performance. Despite having a system that technically worked, we encountered several significant issues that required attention.
One major issue was the inconsistency we experienced throughout the design. Consistent filament extrusion is crucial because it relies on the smooth melting of plastic and the steady dispensing of hot material. We found that every attempt to control the output to compensate for irregularities ultimately rendered the filament unusable. This inconsistency was primarily due to the motor, which produced excessive vibrations because of its size. Additionally, it often struggled to handle the high torque needed for optimal performance, quickly highlighting a significant drawback.
Another critical factor was the heater band we used. We depended on a single heater band to melt the plastic, reaching temperatures of approximately 250 degrees Celsius. However, due to the short length of the barrel, the feeder did not have enough time to warm up gradually before reaching the melting point. This insufficient heating led to the formation of bubbles and popping sounds at the nozzle, disrupting the smooth flow of filament we aimed to produce.
Lastly, the DC motor controller we implemented contributed to the challenges we faced. We needed a more powerful controller to provide smooth pulse-width modulation (PWM), which would enhance the motor’s performance and improve the overall functionality of the system. Addressing these challenges was essential for developing more reliable and effective versions in the future.
Upgrades
Taking everything into account, we decided it was necessary to return to the drawing board to implement some important changes. As shown in the image above, we made significant improvements to the size of the pellet feeder to increase its capacity and storage. Our main focus was on enhancing the torque; to achieve this, we incorporated a chain design into the system and upgraded to larger motors for better performance. Additionally, we included extra electronic accessories that allow us to monitor the entire system more effectively while providing valuable feedback during operation. Moreover, we implemented a simple water bath system to cool down the spool immediately after the material is extruded.
These changes proved to be very beneficial, and our extruder began to perform exceptionally well. However, we discovered one more clever improvement that further enhanced our design, leading to the creation of the V3 model as our final version.
The entire project took around six months to complete, influenced by tight deadlines and the fact that this was our first attempt at such an exciting and innovative endeavor. Since then, we have added several other variations to our design, which we will be excited to discuss in more detail shortly, so stay tuned for more updates and insights!
Results
