Advanced Applications of Desktop 3D Printers

By Erick Wolf

Types of 3D Printing Technologies

Type Technologies Materials

Extrusion Fused deposition modeling (FDM)Thermoplastics (e.g. PLA, ABS), HDPE, eutectic metals, edible materials

Wire Electron Beam Freeform Fabrication (EBF3) Almost any metal alloy

Granular

Direct metal laser sintering (DMLS) Almost any metal alloy

Electron beam melting (EBM) Titanium alloys

Selective heat sintering (SHS) Thermoplastic powder

Selective laser sintering (SLS)Thermoplastics, metal powders, ceramic powders

Powder bed and inkjet head 3d printing, Plaster-based 3D printing (PP)

Plaster

Laminated Laminated object manufacturing (LOM) Paper, metal foil, plastic film

Light polymerizedStereolithography (SLA) photopolymer

Digital Light Processing (DLP) photopolymer

Model

• A Model is made with CAD software • Or from scanned images

gCode

• Model is “sliced” into layers• X, Y, Z coordinates

Object

• 3D Printer uses gCode• Deposits plastic, layer by layer

The Basics: How it works

Model is made

Design a model with CAD software such as: Solidworks, AutoCad, SketchUp

From a 3D scan of an object Download a free 3D model from many

sources

Many ways to a 3D model

gCode is Generated

A 3D model is saved as an STL format The STL file is “sliced” gCode is X Y Z coordinates, speed,

temperature and more

gCode

3D Printer Deposits Plastic

3D Printer takes gCode Melts plastic Deposits layer by layer

Additive manufacturing

Each layer of plastic is deposited on top of the previous layer

The warm plastic bonds to the prior layer With each layer, an object slowly materializes

Filament

Materials: Called filament Standard size is 3mm and 1.75mm Looks like Weed Wacker wire Typically available in 1 or 2 pound spools. 1 pound of ABS filament = $48

ABS PLA PLA 4043D Nylon 618 Nylon 645 Bridge Nylon LayWOOD HIPS Soft PLA TPE

LayBrick BendLay T-glase Colorfabb XT PVA Polycarbonate PET BronzeFill PC/ABS TPU

25+ Materials That Are Readily Available For Desktop 3D Printing

Impact resistance and “toughness”◦ Most commonly used thermoplastic◦ Legos, automotive trim components, automotive bumper bars,

enclosures for electrical and electronic assemblies◦ Useful characteristics within a temperature range from −20 to

80 °C (−4 to 176 °F) 3D Printing

◦ Stronger, more stable (long term), and less brittle than PLA, handles higher temperatures

◦ General rule/design consideration – printed parts have 30% the strength of injection molding

Available in all colors, including gold, silver, fluorescent hues and glow in the dark

ABS - Acrylonitrile Butadiene Styrene

Parts For 3D Printers“We use this material to make almost every plastic component on the Airwolf 3D printers because of its ease of printing and resistance to high temperatures.”

-Airwolf 3D

ABS Example

ABS Has many Post Processing Possibilities

Prints well straight on glass with Wolfbite (www.aw3d.com)

Print Temperature: 240-250°C

ABS – Optimal Settings

Heat bed REQUIRED◦ Capable of at least 120C necessary for proper adhesion◦ Risk of curling without proper surface preparation

Large Prints will crack if not designed carefully or if enclosure is not present◦ Tall prints need to printed quicker◦ Add perimeters for strength

Heated build volume◦ Can quickly wear components (motors, bearings, plastic)◦ Servicing inconvenient

ABS – Considerations

Environmentally friendly◦ Made from starch rich plants such as corn, wheat, and sugar

beets Starch is separated and dextrose goes through fermentation process

◦ Bio-degradable and compostable Commercial compost – 30-45 days

Easy to print◦ Fun, smells pleasant (like waffles)◦ Little-to-no warping

Available in all colors, including gold, silver and fluorescent hues (even hybrids)

PLA - Polylactic Acid

30” Batmobile

PLA Example

Does not require a heated bed◦ Prep surface with Airwolf red tape for best adhesion

Fans on the extruder are mandatory◦ Fans on extruder reduces chance of jams◦ Fans on print surface can help cool printed surface for

appearance benefits Minimize excessive retraction Melting point: 195° - 220°C

PLA – Optimal Settings

Perfect for large demonstrative models◦ Little surface tension, so minimal chance of cracking◦ No need for heated build chamber

Print time is not an issue◦ We have printed for 5 days straight with PLA without warping/cracking

However, will change form in direct sunlight◦ Cellphone cases left in car will distort in less than a day

Functional prototypes should be treated

PLA – Considerations

Taulman 3D 618, 645, Bridge Nylon Filament Nylon based co-polymer Excellent surface bonding Reduced water absorption and tear resistance Color: white/clear Dyeable Bridge

◦ Tends to be more flexible, but less susceptible to warping◦ Print at 270C with bed at 60C◦ Pet tape with glue stick for adhesion ◦ Used for Airwolf gears

Nylon – Co-Polymer

Polycarbonate is an extremely strong, impact resistant thermoplastic

Bleeding-edge technology and is currently experimental

Used in Airwolf extruders for heat resistance Unlike acrylic or plexiglass (they shatter and

crack), Polycarbonate tends to bend and deform and after much effort will eventually stretch like very hard rubber until it eventually breaks

Hygroscopic and will absorb moisture from the air

Polycarbonate– Experimental Thermoplastic

Polycarbonate – Sample Part

Extruded at or above 300C for best layer-layer adhesion

Many current 3D printer extruders are not compatible with temperatures above 250C Make sure your printer is capable of these temperatures or your extruder may fail

Print surface is PET tape and then glue stick on top of that

The faster and hotter an object is printed the more clear the end results

Polycarbonate – Optimal Settings

Combination of Polycarbonate with ABS Extruded at or above 280C for best layer-layer

adhesion (advanced extruder needed) High heat distortion is an improvement over ABS Low temperature impact resistance gives it an

advantage over polycarbonate. Works excellent for small/midsize prototypes that

need to “function” Heated chamber preferred for large, complex builds Print surface is PET tape and then glue stick on top

of that

PC/ABS – Plastic “Alloy”

The printed wood will appear rough, similar to MDF (Medium-Density Fiberboard)

Paintable, grindable, carvable and stainable Heated bed is not necessary Available in two shades of brown Similar thermal durability as PLA

LAYWOO-D3 – Co-Polymer with recycled wood

LAYWOO-D3 – Example

Heated bed ideally at 60C Print Temperature: 175°C to 200°C Prep surface with blue painters tape Adding extra extrusion to the beginning of your print

will help prevent dry extrusion during the initial layers Increasing the retraction setting of your part during

slicing will reduce 'leakage' while the hotend is moving between sections (especially over open areas)

LAYWOO-D3 – Optimal Settings

LAYWOO-D3 will harden over time, for delicate parts allow 30-60 min for your print to set

Alternating the temperature during your print (even by as little as 10 degrees) will vary the coloration, giving it a 'grained' look

High Impact Polystyrene is very similar to ABS in its printing properties, but works with different solvents (Limonene for HIPS vs acetone for ABS)

Easy to paint and glue When printing, best to keep bed temps at 100C

or lower, but extrusion at normal ABS temps works fine

Color: White Use for support material on HD2x and use

solution to remove support material from part

HIPS – High Impact Polystyrene

Water-soluble synthetic polymer It prints very easily and can be used as wash away

support structure when using more than one extruder

Can be used with a dual extruder 3D printer to add support materials

Best printing comes with a 100C heated bed and slightly lower temps than ABS (190-210C)

Color: Off white Dissolves in water !!! (quickly) Like Elmer’s glue

PVA – Polyvinyl Alcohol

Soft PLA is a flexible 3D printing material that feels and acts much like rubber

Support built into prints can be easily removed (unlike traditional PLA)

Can be used to make parts that can bend or must flex to fit their environment - stoppers, belts, springs, phone cases and more

Biodegradeable

SOFT PLA – Polylactic Acid

SOFT PLA – Sampled Part

Layer height is best kept down to maximize layer-to-layer bonding because the parts need to be extra strong as they are flexed in use

Recommended Extrusion Temperatures: 200C-215C Sticks well to a bed that is layered with blue

painters tape Slow print speed for best results Keep bed at 60C

SOFT PLA – Optimal Settings

Also referred to as “thermoplastic rubber” High elasticity: Extremely flexible and strong 3D printed TPE feels much like rubber and

bounces back into shape REACH and RoHS 2002/95/EC Directive Compliant Filament shore hardness of approximately 85A Available in Red, Blue, White and Black

TPE – Thermoplastic Elastomer

Sample PartWashers

TPE

Prep platform with blue painter’s tape

Recommended extruder temperature: 240°C

Recommended platform temperature: 40°C

TPE – Optimal Settings

Has a grey stone color Allows you to give your prints a smooth or stone-

like texture Ideal for jumbo-printers Objects are paintable and grind-able Contains super-fine milled chalk and harmless co-

polyesters

LAYBRICK – Mineralic Fillers and Co-polyesters

Sample Object

LAYBRICK

You can print LAYBRICK in a range of about 175°C to 210°C

In the lower range, the print will come out mostly smooth, whereas at higher temperatures it will begin to have a sandstone-like texture

Prep surface with blue painters tape It is recommended to use a fan when printing at

higher temperatures (always to avoid jamming)

LAYBRICK – Optimal Settings

Extremely translucent (91% of light passes through) and is also flexible

Print nearly clear items Safe for household and food products Compared to ABS it also absorbs far less

moisture from the air and thus cuts down on warping significantly

Soluble in brake cleaner

BendLay – Modified Butadiene

Sample Part

BendLay

It sticks great to a bed that is layered with blue painter’s tape or on PET film with Elmer’s glue stick

Print it at a slower speed (around 20-30mm/s) than normal materials

Compared to ABS it also absorbs far less moisture from the air and thus cuts down on warping significantly

Extrusion Temperatures: 230°C-240°C

BendLay – Optimal Settings

A low temp (212C) industrial 3D printing material Considered “water-clear” and “optically correct” A low TG means that parts printed in T-glase,

should not be exposed to high temperature use or applications.  The measured TG of T-glase is 78C

Made of FDA approved polymers for direct food contact/containers

Not biodegradable like PLA however it is a considered 100% reclaimable

There are supposedly no odors or fumes when 3D printing with T-glase

T-glase

T-glase– Sample Parts

Optimum temperature is about 212c to 224C, but will print down to 210C and up to about 240C (depending on speed)

T-glase easily sticks to heated acrylic and glass print tables (with PET film) for the smoothest bottom surface possible

 Very low shrinkage makes printing large flat surfaces a breeze

Prints to acrylic, glass, Kapton and other platforms

T-glase – Optimal Settings

Concept: Photos of your feet are turned into 3D

models Select FeetZ shoe elements and shoe

is custom made to form and function needed

FeetZ 3D prints shoes in TPE

Leading the SizeMe Revolution

"Tests are good so far," Lucy Beard says, holding up an example of a cute,

very flexible and comfortable looking ballet

flat. Source: SAN DIEGO CITY BEAT

Pioneering intercontinental robotics: Uses 3D printers in its design and

manufacture of telepresence robots Large build platform of 12” x 8” and

heated bed enables Orbis to print larger parts of the robots with a 3D printer

The face of telepresence

“Our low overhead approach to design and manufacturing

permits us to respond quickly to the ever changing

market of robotics.”  -CEO Steve Gray

Questions?

Erick Wolfwww.airwolf3d.com

(949) 478-2933

?