Print of the day: Split Patterns for casting valve bodies

What we printed today! Split form patterns for casting a 90lb steel safety valve. We firmly believe that casting is one of the right applications for large format filament printing! 

  • 1mm Nozzle
  • ABS Material
  • 1.8kg
  • 10" x 12" x 6" 
  • 13hr print time
  • 4,400 mm/min
  • 75C chamber temperature

 

Note the steaming popping in this part. It's due to the ABS picking up moisture during the printing process. We're working on a heated vacuum spool cart to help prevent this problem. It's a tough one!

After one application of Evercoat Featherfill. Never again apply bondo by hand! Take about 10 minutes to spray and 20 minutes to sand. There is a time/resolution tradeoff that is always present with printing. For larger prints, it's often times better to choose a larger layer thickness to save 12+ hours in printing, and perform a half hour of post processing to achieve the final desired surface finish. 

 

 

 

 

 

 

 

 

Print of the day. Variable Layer "Time is Money" Tower

This is what we call the "Time is Money" tower.  There is a constant desire to have the best possible surface finish with prints, but it comes at the price of time. We're created a sample that shows this concept very plainly. Each one inch section of the tower is done at a different layer thickness. 

.1mm layer = 360 RMS = 102 minutes

.2mm layer = 590 RMS = 51 minutes

.3mm layer = 720 RMS =  35 minutes

.4mm layer = 950 RMS = 26 minutes

.5mm layer = 1100 RMS = 21 minutes

Polycarbonate-PBT Wing

What we printed today! This was a monster print. PBT is used extensively in the electrical industry and remains largely undiscovered in the 3d printer world. The PC-PBT (https://www.sabic-ip.com/gep/Plastics/en/ProductsAndServices/ProductLine/xenoy.html) has amazing strength and stiffness, but for a print this large it requires a HOT chamber. We ran at 100C for the duration of the print. 

  • 1mm Nozzle
  • ABS Material
  • 7kg
  • 32" x 12" x 10" 
  • 72hr print time
  • 2,500 mm/min
  • 100C chamber temperature

850mm PETG Pedestal Vase for Houston Maker Faire

We attended the Houston Maker Faire and printed these pedestals to giveaway. Using vase mode we experimented on how quickly we could print. Turns out it was quite a bit faster than even we expected! These prints were coming off at a rate of almost 3 per day. 

  • 1mm Nozzle
  • PETG Material
  • 2.5kg
  • .45mm layer height
  • 850mm x 350mm x 350mm 
  • 9hr print time
  • 5,000 mm/min
  • 50C chamber temperature
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