A 100% Plastic 3D Printer?

Many designs of self-reproducing 3D printers have been produced and built; that’s the goal of the RepRap project. But are they truly reproducing themselves? 

 

Not exactly; the machines are - so far - only capable of reproducing most of the major  plastic components, such as the image above, which was apparently the very first 3D printer part produced on a RepRap machine. Some plastic components are beyond the temperature envelope of current 3D printers. Metal components have not yet been reliably produced by such machines, and certainly the complex electronics have not yet been produced by replicating 3D printers. 

 

But there is hope. Many researchers continue to work on this challenge and we see machines capable of 3D printing in metal and others experimenting with 3D printed electronic circuits. None of the electronics experiments are anywhere near capable of 3D printing the complex CPU and other chips, however. Once these technologies are developed, it then remains a task to put them all together into a single machine that can, finally, print all necessary parts for reproduction. 

 

But then, of course, you’ll have to assemble all those pieces. Self-assembly is yet another major challenge.

 

Image credit: Wikipedia

The Fusematic 3D Printer

Maker’s Tool Works has announced a new 3D printer kit, the Fusematic. It succeeds MTW’s previous model, the MendelMax 2 by being “smaller, faster, and more affordable”. 

 

MTW simplified assembly by including assembly guides on the case, using linear rails, preassembling and pre-loading the electronics and keying the connectors. 

 

After assembly, you’ll find the Fusematic performs well as it encloses all electronics, which were exposed on the MendelMax, prints faster with a lighter Bowden extruder and it’s easier to calibrate. 

 

The device actually has a smaller print volume than the MendelMax 2: 200 x 225 x 200mm, still quite reasonable. 

 

The base machine is set up for printing PLA plastic only; if you want to print ABS and other “hotter” and warpy materials MTW recommends purchasing their optional heated bed. You also get a choice of 1.75 or 3.00mm filament capability.  

 

For now you can pre-order a Fusematic kit for only USD$799 (add USD$50) for the heated bed option. Shipping is expected mid-January. We think this could be a good choice for an inexpensive yet well-designed 3D printer. 

 

Via Maker’s Tool Works

This 3D Printer is Truly a Monster

Ben Reytblat’s new venture, 3DMonstr, has attracted some attention on Kickstarter, where the pledges are flowing in rapidly for the new 3D printer. 3DMonstr is actually a family of fully assembled 3D printers, each of which entirely deserving of the “monster” label. 

 

Sure, it’s size that is the major factor. The “small” version, the T-Rex-12 has a print volume of 305 x 305 x 305mm, or in Imperial terms, one cubic foot. There’s a T-Rex-18 and a T-Rex-24, with a staggering 610 x 610 x 610mm build volume, or eight cubic feet. As you might imagine, these are not small machines, weighing from 75 to 150 pounds without filament. 

 

As large as they are, the T-Rex’s are said to be portable. They can actually fold easily into transportable volumes. 

 

It’s not just print volume the 3DMonstr’s exceed at. They’re capable of handling up to four different extruders. Presently the extruders can work with plastics, but the intention is to offer extruders capable of printing food grade material, low temperature squishy substances and very inexpensive plastic pellets. A quick-mount mechanism enables easy extruder changeout. 

 

A concern with large-format 3D printers must be reliability. For printing large objects, which you must be doing otherwise you wouldn’t buy a 3DMonstr, much time will elapse, particularly if you print at 0.04mm layers, the best quality layer size available. During that long print time the printer had better be very reliable, lest you waste a ton of plastic on that half-built eighteen inch gnome. Based on their intentions, it seems that the 3DMonstr team understands this and has spent considerable effort re-engineering their designs to meet the challenge. Be sure to watch their video where all these features are demonstrated - especially when Reytblat takes a blowtorch to the machine to prove its durability. 

 

But how much will these enormous printers cost? It depends on the print volume and the number of extruders you required. But in all cases the price will range from USD$2,499 for a single extruder T-Rex-12 to USD$4,999 for a four-extruder T-Rex-24. 

 

Via Kickstarter

The LulzBot TAZ 3 Personal 3D Printer

LulzBot has released a new version of their popular TAZ personal 3D printer: 3.0. The new version includes several evolutionary improvements, including additional metal parts and a quicker-to-print-ready heated bed. 

 

The TAZ is an open-air 3D printer, meaning the heated bed is more important to avoid warping if you’re printing ABS plastic. TAZ has some impressive specifications: 

 

• Large build volume of 298 x 275 x 250mm
• Layer size as small as 0.075mm - although prints at that resolution would take a long time! 
• Supported 3.0mm filaments include: ABS, PLA, PVA, HIPS, Wood

 

We’re quite impressed with the toolkit that comes with each TAZ: 

  

• Toolkit bag
• 15 Piece Metric Hex Key Set
• Pliers, Needle Nose
• Tweezers
• Standard Precision Knife
• Dental Pick
• Flathead Bristle Brush
• Part Removal Knife (clam knife)
• Metric Ruler
• Acetone-safe Bottle (acetone not included)

 

The acetone bottle is a very nice touch for those that intend on smoothing their ABS prints. About the only thing more we’d want is a digital micrometer, but the TAZ toolkit will definitely work for you. 

 

If you have USD$2,195 burning a hole in your wallet and able to wait 1-2 weeks for shipping, you too can have a LulzBot Taz in your possession. 

 

Via LulzBot

The RepRap Industrial

RepRap 3D printers are for hobbyists, right? For tinkerers who like to build their own machines? Not always, if you were to ask the brothers Kühling & Kühling, who produce the RepRap Industrial 3D printer. 

 

This machine is a pre-assembled RepRap machine specifically designed for industrial use. What makes it so? We noticed multiple features: 

 

• It's big. The machine has a huge exterior size compared to typical RepRap machines, with a reasonably-sized build platform
• The build platform, and in fact the entire machine is enclosed in a well-lit, sealed chamber, which is heated to +70C for warp-free 3D printing in nylon or ABS for objects over 20cm in size
• It might seem that the build chamber could be larger, but it isn't to permit heated air flow to circulate through the chamber
• Very heavy-duty internal components are used throughout
• High-capacity filament spools (up to 2.3kg each) can be mounted on the rear panel of the machine
• A "filament out" detector pauses prints to permit you to replace a spool
• An embedded computer spools incoming print jobs into a queue. While it doesn't yet remove prints from the bed automatically, once you do the next job is ready to go

 

In addition to standard features such as 0.1mm resolution, dual extruders and network connectivity, the RepRap Industrial includes a very attractive touch screen connected to the embedded computer. 

 

We'd class this device as a "professional" machine, suitable for heavy usage. Priced at €5,000 (USD$6,850), the machine is not inexpensive - but it will likely outlast several lesser machines. 

 

If you want to buy one, be prepared for a bit of a wait. We understand there's currently a sixteen-week backlog of orders, but that might drop as manufacturing capacity is increased. 

 

Via Kühling & Kühling

A Personal 3D Metal Printer: In Progress

We're checking out a project that's listed on the RepRap Wiki: MetalicaRap. The goal is to produce a:

 

Open 3D metal & home solar cell printer, based on the principles of electron beam welding and vapor deposition.

 

No, it isn't ready yet - the project is still in the planning stages. While the primary objective of the project is to enable the inexpensive production of home solar cells, we're particularly interested in the ability to 3D print metal objects. 

 

The process to be used involves a powerful 300W electron gun firing into a vacuum chamber to melt metal powder. By repeatedly applying layers of metal powder and solidifying portions, metal objects are gradually built. 

 

The project's specifications are modest, considering the technological challenges it faces. In addition, this machine will be able to "largely" replicate itself, including the electron gun.  

 

This manufacturing process is unlike others attempted in the personal 3D printer space, generating unique challenges. For example, the 0.01mm metal powder is so small it can be affected by minor magnetic disturbances. Vacuum chambers are not required on typical personal 3D printers, but they will be required here. 

 

It's expected the MetalicaRap, when built, would cost thousands of dollars just for the components. 

 

The project has been open for over a year, but it appears they have lots yet to do. When MetalicaRap is finished it will be interesting to see how it changes the 3D printing community. Will we have 2.4m tall metal printers in our workshops? 

 

Via RepRap Wiki

A 3D Printer Made From Scrap

Normally when you embark on building a DIY 3D printer you'd search online shops for the best and least expensive components. Bring them together with the right plan and you'll soon have an operating 3D printer. 

 

But that's not exactly what Kodjo Afate Gnikou did. He went to the dump. Specifically, he searched through piles of e-waste to find leftover components to find "rails and belts from old scanners, the case of a discarded desktop computer and even bits of a diskette drive". 

 

With that and USD$100 worth of new bits that could not be found in the dump, Gnikou was able to make a working 3D printer. 

 

What's hiding in your dump?

 

Via Euronews

DealExtreme Sells 3D Printers

Another major retailer sells 3D printers: Deal Extreme, one of the more popular online shops for electronics equipment, now sells the Heacent 3D printer kit. 

 

The Heacent 3DP02 kit is from a Chinese manufacturer and is based on the tried-and-true RepRap Prusa Mendel design. It's specifications include a 200x200x100mm build volume equipped with a heated print bed; 0.3mm nozzle capable of extruding PLA and ABS plastic (and anything else you'd like to try as well). 

 

 

The key feature for this product we believe to be the price: USD$674, including free shipping, one of the least expensive 3D printer kits you might encounter. That will get you a Heacent kit that you'll enjoy putting together. If you think the 3DP02 is still too pricey, perhaps you'd consider the other Heacent available at Deal Extreme: the Heacent 3DP01, currently marked down to USD$640. 

 

Via DealExtreme

Print Bigger: The gMax 3D Printer

A Kickstarter project is launching the gMax personal 3D printer. It's claim to fame is a whoppingly huge build volume, hence it's name. 

 

gMax is designed by Architect Gordon LaPlante of Brooklyn, a hotbed of 3D printerness. His story: 

 

As much as I loved the RepRap, I found myself being limited by the bed size. While I love the idea of sourcing parts from the community, there were larger objects I wanted to print but simply wasn’t able to. I then started playing around with designs for a larger 3D printer and eventually the idea started to grow legs and become something tangible. I sourced the latest electronics and a strong aluminum framework and used my RepRap to print the parts I needed to build what would become the gMax 3D printer.

 

Necessity is the mother of invention in this case. The gMax does have a monstrously huge build volume for a personal 3D printer: 16 x 16 x 9" (406 x 406 x 229mm), or 2,304 cubic inches (almost 38 litres!) 

 

 

One interesting feature that supports (literally) the large build volume is more robust frame extrusions. While most 3D printer kits use 1" aluminum spars, the gMax boasts 1.5". 

 

You won't sacrifice accuracy for the large size, either. The gMax is capable of printing layers as small as 0.075mm in 1.75mm ABS or PLA plastic. We're not sure how successful warp-ridden ABS printing will be at that size, but you can certainly make an attempt. 

 

The machine is also designed for easy assembly and maintenance, with many parts having simple swap-out capability. 

 

The gMax can be pre-ordered on the Kickstarter page for USD$1295. For that you'll receive a full kit complete with all required parts. 

 

We're not fans of large prints due to warping, time delays and the higher probability of failure, but if you need larger pieces printed and have a reliable machine like the gMax claims to be, you'd be all set. Just buy one before October 10th, when the campaign concludes. 

  

Via Kickstarter

It Does Everything: The FABotum

A new Indiegogo project hopes to develop the FABotum, a multidiscipline manufacturing device. Actually, it's full name is the "FABtotum Multipurpose Desktop Personal Fabricator".

 

Wait, what kind of a machine is that? This machine is actually a combination of several manufacturing processes, including 3D printing. The FABotum also includes CNC (cutting) capability and 3D laser scanning, too. 

 

The 3D printer function appears to be comparable to standalone 3D personal printers: up to 0.1mm layer size; prints PLA and ABS plastic filament and has a 210x240x240mm build volume. 

 

The CNC function includes a spindle that holds a bit for milling, and it can apparently be moved along four axes for excellent access. The spindle motor is only 30 Watts, and therefore can cut only very light materials like foam and balsa wood. Engraving on harder materials is possible, however. 

 

The 3D scanning function involves two processes: laser scanning and touch scanning. The laser function provides limited accuracy scans, while the touch mode involves using the highly accurate Z-axis to raise and lower a fine probe to gather height information on a scanned object. 

 

The FABotum is being developed by a team from Italy, who hope to raise USD$50,000 by October. They're well on the way to achieving that goal. It looks like the target price for a fully assembled FABotum will be USD$1,099, or perhaps higher after their launch. 

 

Interestingly, the FABotum has peculiar licensing terms. The project seems to have intentions of open sourcing as much as possible, yet they have obtained patents on the "FABtotum technologies". They will permit development of third party "heads" for the moving part of the machine, yet provide "full documentations,drawings and the reproduction of FABtotum is allowed and encouraged under the Creative Commons Attribution-Noncommercial-Sharealike 3.0 Unported Licence." 

 

We're not entirely certain what this means. 

 

Regardless, this machine is unique. It combines multiple open source manufacturing technologies into a single, affordable box. We think this is a very challenging project; the software alone will be a complex combination of different approaches. Nevertheless, if they pull it off it could be the beginning of a new product type: personal fabricators. 

 

Via Indiegogo

The Isis One 3D Printer

There's quite a story behind the design of the Isis One personal 3D printer. The creators of this just-released device recognized the numerous problems inherent in current RepRap machine designs: first layer adhesion, bed leveling, Z-axis stability, noise, support structures, extrusion skipping and much more. 

 

Their engineering team methodically pursued each issue, gradually building the eventual Isis One design. Their goal was to produce an inexpensive machine that could rival the big commercial extrusion-based 3D printers. Here's some of their innovations we found interesting: 

 

• 12mm steel rods introduce much more stable and consistent linear movement
• Glass bed design requires leveling only once at the factory
• New method of adhering the first layer to the print bed (hairspray!)
• Extruder improvements to reduce or eliminate oozing, delimitation, warping, wobble, overhang drips
• Pre-calibrated KISSlicer Pro software that generates excellent break-away support structures

 

The feature we're most interested in is the support structures. If they've actually pulled this off (no pun intended), then the restriction of "flat bottomed parts" goes away forever. Simply print ANYTHING and it will come out of the machine. This could be a huge step forward. 

 

 

The sample print images show some extremely well-done prints (click for larger view). This could be a terrific machine. 

 

 

The Isis One's specifications are excellent: 

 

• Build volume of 300 x 300 x 225 mm (12 x 12 x 9 in) 
• Layer size of up to 0.05mm
• Prints in ABS, PLA, Nylong and Polycarbonate
• Priced (assembled) at USD$2199

 

One concern was the fact that the Isis One uses 3mm filament instead of the now defacto industry standard of 1.75mm. We asked Isis spokesperson Steph Avalos-Bock:

 

After extensively testing both, we chose 3 mm filament mainly because it allows higher print speeds; there's only so much 1.75 you can push through a nozzle. The other big benefit is that you can tighten down the extruder much more than for 1.75 without the filament stripping. This allows more consistent extruder performance and doesn't rely on an end user finding the small sweet spot that 1.75 requires. 

 

The Isis One design is intended to introduce reliability so that owners can spend time printing instead of fixing. They say: 

  

You can print dozens of complicated parts at once without fear of drama.

 

Drama. We like drama. Just not on our 3D printer. 

 

Via Isis3D

D3D's Unusual Extruder

While some develop 3D printers, others work diligently developing subcomponents. The extruder is particularly devilish, as it must withstand the most force and temperature of any part of a filament-based 3D printer. 

 

Wait, why re-invent the venerable extruder? The answer lies in the challenges with multi-color 3D printing. Current 3D printer manufacturers simply "add another extruder" to their machine to gain multi-color capability. Some machines even have a third or even fourth extruder installed. But as each extruder is added, you lose lateral movement within the build volume. In other words, the more extruders, the smaller the objects you can build. Not good. 

 

 

D3D, a project by Carl and Brian Douglass, have designed a Dual and Quad extruder that hope to overcome this growing issue. Their design involves a rocking mechanism that re-uses some of the mechanics for a second extruder path. Because only one filament can be engaged at a time, the Dual (or Quad) extruder's rocker tips to one side or the other to access each filament. 

 

This technology is quite advanced for personal 3D printers - but is somewhat reminiscent of the mechanics inside a Stratasys uPrint extruder. Perhaps D3D should check the Stratasys patents before they proceed? 

 

 

Nevertheless, if produced, the D3D should enable an explosion of two and four-headed personal 3D printers because it should be compatible with a great many open source 3D printer designs. 

 

That and a lot of filament purchases. 

 

The project has a Kickstarter goal of USD$25,000 by September 13th to proceed. They're not at that level yet, but this project looks more than sufficiently interesting and should easily get to that level. 

 

Via Kickstarter