4 Tools and 1 Carriage Box to Rule Them All…
Using Cosine’s modular carriage box, the user has access to the full catalog of Cosine tools. By swapping the included hardware, the operator can plug-and-play any tool they want. While some tools may require additional support hardware (material transfer tubes, motor adapters, specialized mounting hardware, additional logic components, etc.), they all integrate easily into the Cosine system. Every tool has full software interface support and can be controlled with just a few clicks.
Filament Extruder:
Our filament extruders feature a standard dual gear, direct-drive filament feeding system. They are designed to be jam-resistant, easy to maintain and achieve constant high-volume extrusion. The Cosine filament extruder is capable of max extrusion rate of 1 lb/hour. Utilizing open-market materials, the operator can use any kind of material they want.
With a billet aluminum body and hardened steel nozzles, these extruders can handle whatever filament the user throws at it. Sporting a dual melt-zone system capable of reaching temperatures of 450°C+, the filament extruder can extrude any thermoplastics that the operator chooses to use. Coming in a variety of nozzle sizes and even the option for custom nozzle sizes, Cosine has the right extruder for any print job.
PELLET EXTRUDER:
The Cosine pellet extruder consists of a 1500W servo motor coupled with a 20:1 gearbox allowing for extrusion rates of 20 lb/hour. Using a 3+1 melt zone assembly, the extruder can safely reach temperatures of 500°C+. With a construction of a heated-treated barrel and all aluminum body, this tool is just as tough as any material you can throw in it.
Strategic water-cooling allows for critical components to stay cool even when in the high-temp. heated chamber environment. With the option of an automatic pellet feed system, you can have continuous, reliable material delivery during printing, allowing for peace of mind during those extended timeframe print jobs.
All Cosine pellet extruders come with a female threaded end, allowing for interchangeable nozzle sizes. Cosine offers nozzle size ranging from 0.5mm to 8mm and can manufacture custom size nozzles depending on the user’s needs.
MILLING SPINDLE TOOL:
This tool can turn your Cosine printer into a hybrid manufacturing machine. The operator has the ability to pair the spindle tool with additive tools to boost production and shorten lead times. For example, pairing a spindle tool with the Cosine pellet extruder allows the user to print “rough”, near net parts and then milling them to the specified dimensions. This allows the operator to achieve tight tolerance additive parts on much shorter lead times than with only additive manufacturing. Tools are easily interchangeable with almost any milling tool needed for the operation.
A useful application of a combined additive and subtractive job is mold production. A near net form of the mold can be additively manufactured with a pellet extruder. Outside of the cavity face, the looser tolerances of pellet printing are a non-issue for the rest of the mold. The spindle can then run a finishing operation to smooth the cavity surface and mill it with tolerance. This use case leverages the speed of additive manufacturing with the precision of traditional CNC manufacturing.
Cavity Pump Thermoset Extruder:
Thermoset printing has been heralded by many as the future of additive manufacturing. Integration of resin extrusion printing technology is imperative to staying on the cutting-edge of 3D printing technology. Cosine’s focus has been on Ambient Reactive Extrusion, which is the extrusion of multi-part resins that chemically cure without the need for additional activation energy. In principle, this works much like a two-part epoxy, where you have Part A that mixes with a ratio of Part B, and the material then cures in a set time.
The Cosine cavity pumps transfer the resins from their storage containers to the print head, where they are mixed and begin curing. The printer’s pumps are designed to allow the operator to precisely control the material mixing and our user interface allows adjustment to the mixing in real time. The ability of real-time mixture adjustment allows for the creation of parts with variable mechanical properties without having to change the extrusion material.
Keeping in theme of open-market materials, the Cosine Thermoset extruder can be used with a catalog of pre-approved and pre-tested materials rated for creating parts for almost any industry such as: Aerospace, marine, automotive, etc.
