1 (edited by 2n2r5 2013-10-09 16:52:23)

Topic: My Filastruder and Results so far! (ABS and PLA)

http://2n2r5.com/pictures/printer/filastruder/filastruder.JPG

I purchased the beta case and had my entire filastruder together in about 1.5 hours. Actually, my girlfriend had it together. This one is going to be hers and she is making me use the Beta one that I picked up from Tim in the Buy/sell/trade section. Either way, the only hiccup so far was reversing the order of the shaft collar and nylon bushing. I didn't catch that before she had the case together and found it only after running some plastic through. A quick shot with the torch help get the plastic hot enough pull out the auger and do a quick rearrange. It also let me double check the work to see that everything else got put together correctly.

We have already run >5 lbs of ABS through this filastruder. The other filastruder is running PLA. I am using it currently to test how colorants mix depending on temperature. I found some interesting results at lower temps (138-142) where the colors just start to blend and make for some cool patterns. I think I am going to get a new temperature controller from Tim since this PID controller is less effective at controlling the temperature than the fan is. Here are some results photos for the PLA.
http://2n2r5.com/pictures/printer/filastruder/custom_filament.JPG
http://2n2r5.com/pictures/printer/filastruder/treefrog.JPG

It was pointed out that I forgot to attribute the artist:
Treefrog from thingiverse designed by MorenaP http://www.thingiverse.com/thing:18479

SD3 w/ mods:
Glass bed with QU-BD heat pad upgrade, threadless ballscrew w/ 8mm smooth rod, spectra line belt replacement, lawsy MK5 extruder, Lawsy replacement carriage, E3D hotend, Ramps 1.4 w/ reprap discount controller, DRV8825 drivers, 12v 30A PS, Acrylic case, Overkill Y-idlers, Filament alarm, Extruder fan + more.

2

Re: My Filastruder and Results so far! (ABS and PLA)

Now that is awesome! It does a lot to lose that layered look when the color can change so rapidly mid-layer. In ABS with acetone-smoothing, the effect would be stunning.

3 (edited by Ralphxyz 2013-10-02 14:28:44)

Re: My Filastruder and Results so far! (ABS and PLA)

2n2r5, where is the cooling fan? Or are you running with out one? Then of course the position of the insulation is not "standard" placement but that is with a fan.

Great frog!!

Ralph

4

Re: My Filastruder and Results so far! (ABS and PLA)

The fan is under the lasercut piece. The insulation is a little bit forward but it's not a huge deal. Better to be a bit forward than really far back.

5

Re: My Filastruder and Results so far! (ABS and PLA)

That picture was taken as soon as It was built and outputting. I noticed that I if I insulated a little better, the motor didn't have to work as hard. I also came up with a filament guide that seems to work a little better. It uses Teflon tubing, 2 washers and a piece of wire.

http://2n2r5.com/pictures/printer/filastruder/frontend.JPG

SD3 w/ mods:
Glass bed with QU-BD heat pad upgrade, threadless ballscrew w/ 8mm smooth rod, spectra line belt replacement, lawsy MK5 extruder, Lawsy replacement carriage, E3D hotend, Ramps 1.4 w/ reprap discount controller, DRV8825 drivers, 12v 30A PS, Acrylic case, Overkill Y-idlers, Filament alarm, Extruder fan + more.

6 (edited by 2n2r5 2013-10-03 02:56:03)

Re: My Filastruder and Results so far! (ABS and PLA)

So far with PLA I have been getting pretty good consistency. I got this PLA from OSP. It has offered great results so far @ 175+- 0.03mm over 10 feet. There was no predry involved. I do keep this filament in a bin with a Golden Rod dehydrator/heater. I have run into issues with ramen but that normally only happens when the temps spike. I try to keep the temps around 138-140C. This makes the motor whine a little and I only get ~5-7 inches per minute. It's a far cry from the 12 inches a minute that I get from my ABS 'struder. I do not have a winder and the nozzle is at a height of 40" and the fan sets at a 15 degree angle 1/2" from the filament. I have managed to get about 100' of perfect extrusion with out too much hassle. Here are a few samples that I printed with it. One thing that you will notice is the moire is very prominent. I do not believe the filament caused that. I ended up having a stepper driver go bad shortly after printing those prints. I think they are unrelated.
http://2n2r5.com/pictures/printer/filastruder/PLA_sample1.JPG
http://2n2r5.com/pictures/printer/filastruder/PLA_sample2.JPG

I love the transparency of the natural PLA. It is a shame to mess it up with color, but that is exactly what I did.

You can see the color filament in the original post. Here are the particulars:
Size: 1.60mm +-0.05 (measured every foot for 10')
Colors:    Yellow - 70:1, Blue - 100:1
Temperature: 138-145C fan controlled
Height of Nozzle:  40"]
Pellet conditioning: None/stored in dehydrated storage bin
Fan Settings: 15 degree angle 1/4" from filament


Notes: I had a lot more trouble with the filament after putting master batch in it. It almost seems as if the colorant holds heat better than the natural and stretches easier under the weight of the filament. I have seen that you aren't supposed to let the PLA fall under its own weight but that only seems to ring true for the colored PLA. (for me at least) I am going to add a second fan to my PLA 'struder and put a duct on it. I am hoping to get the filament to go solid < 1/2" from the nozzle. I will update then.

SD3 w/ mods:
Glass bed with QU-BD heat pad upgrade, threadless ballscrew w/ 8mm smooth rod, spectra line belt replacement, lawsy MK5 extruder, Lawsy replacement carriage, E3D hotend, Ramps 1.4 w/ reprap discount controller, DRV8825 drivers, 12v 30A PS, Acrylic case, Overkill Y-idlers, Filament alarm, Extruder fan + more.

7

Re: My Filastruder and Results so far! (ABS and PLA)

Regarding speeds - IIRC both of your motors are of the old variety. Yo'll get about 80% more speed with the newer ones.

8

Re: My Filastruder and Results so far! (ABS and PLA)

elmoret wrote:

Regarding speeds - IIRC both of your motors are of the old variety. Yo'll get about 80% more speed with the newer ones.

Where do i get a new one ? I want faster extrusion too smile

9

Re: My Filastruder and Results so far! (ABS and PLA)

You already have it.

10

Re: My Filastruder and Results so far! (ABS and PLA)

I have been extruding mg94 for the past several days and here is my experience and setup. I tried horizontal with the stock nozzle with mg94 with temps from 170-200 and could not get above 1.4. I drilled out the nozzle to 1.8 and hung it vertical at 40 inches.  I am using 184 degrees and I am now getting a steady 1.67-1.69. All sorts of colorants as well like red blue yellow and brass. The filament coils nicely below into a 2.5 foot circle. Its taking about 18 hours for 4 pounds so whatever that speed equates to. Overall after having some issues with assembly I think I have it tuned in now. Printing between 230-235 and getting wonderful results.

11

Re: My Filastruder and Results so far! (ABS and PLA)

colorants effect your diameter. They make it smaller by about 0.05-0.1
I noticed that measuring same coil that was well colored VS not so much.

12 (edited by agilliam 2016-01-05 23:33:33)

Re: My Filastruder and Results so far! (ABS and PLA)

I finally mastered extruding PLA at a consistent 1.73 - 1.77 diameter. I have not however mastered mixing colors to get a nice even blend, but this is a cool sample. I'm pleased with consistency in print, layers are great and adhesion is perfect. Wish colors were as consistent lol.

http://soliforum.com/i/?EAemU5C.jpg
http://soliforum.com/i/?Tlgq1k9.jpg
http://soliforum.com/i/?Sc2ZSI1.jpg
http://soliforum.com/i/?Ydthjgy.jpg

13

Re: My Filastruder and Results so far! (ABS and PLA)

The pros (commercial filament) achieve color consistency by pelletizing and re-extruding. If that is not an option, the next best thing is making the colorant/masterbatch pellets smaller using a coffee grinder or similar. The smaller the pellets, the better the color consistency will be - though pelletizing/re-extruding will always be best.

14

Re: My Filastruder and Results so far! (ABS and PLA)

Wow, I did not even think of a coffee grinder. That makes perfect sense though allowing a better mix.

One of my problems I cant overcome yet, because I am not that well with designing using sketchup or the others, is my spools like from FlashForge (I was told they were octave?) the hub is recessed into the spool so it drags and grinds on the nano of the winder. I have some others too like a spool from geeetech (junk I know) and the hole is bigger and the gear that comes with the filawinder just barely fits the hole but it too rubs. Is there any one that has made a gear side that has a larger sized cone to fit these types?

I wish I was better with these programs but when it comes to gears, blah, I cant do crap yet. lol..

15

Re: My Filastruder and Results so far! (ABS and PLA)

You can actually put the PCB on the other side of the board, and it will still work.  You will just need to flip the magnet over since the other side of the hall sensor will be facing the gear and needs the other pole.  The magnet should still be close enough, but you can let it stick out of the gear a bit just to make sure.

16

Re: My Filastruder and Results so far! (ABS and PLA)

AHH! Good Idea!  Looks I will need to do that. I need to look at the BOM and order a new hall sensor.

Thanks for that idea Ian!

Question about the hall sensor on that filawinder..... It seems I almost have to have the magnet within 2mm of the magnet, or else it wont pick up. and its oriented the correct way, I didn't do like you show in your video of spinning it and let it settle. Instead of used tweezers and moved it past the hall sensor and flipped ends till it moved. Even then I had to drill a tiny hole through the gear to push the magnet out a little and bend the hall sensor out to the magnet. Otherwise it doesn't seem to pick it. up. The shield is quite simple and nothing can really be failed there, so I cant figure out if maybe the hall sensor is bad? The magnet is super strong so there is no question about the magnet..

17

Re: My Filastruder and Results so far! (ABS and PLA)

Ian, so as an update, I put the shield/nano on the other side of the winder, made tons of room now. Thanks for that suggestion. However the stinking flashforge spools still doesn't go. But my other spools do that wouldn't fit prior!!

I did create something for the filastruder community. I saw funnels out there but didn't like the way they went into the throats of the bottle reducing size and flow volume. So, instead I modified 2 other "things" on thingiverse and created a funnel with female threads! Works great!

http://www.thingiverse.com/thing:1250555

Hope you guys can use it, it has made my life easier as far as filling small coke bottles for test runs as well as larger 1 liter and 2 liter for production runs!

18

Re: My Filastruder and Results so far! (ABS and PLA)

Any advices you can give me on extruding PLA? I'm currently testing with several extrusion speeds, temperatures and different nozzle hole diameters but I have not been able to extrude at a consistent diameter.
I have found that the best extrusion temperature for PLA (at least on my case) is 140 Celsius, but I have not found a proper balance of extrusion speed and nozzle diameter. Already tested 1.5mm and 1.5875 nozzle holes, 1.5 results in 1.55m ~ 1.64mm filament, and 1.5875 makes the filament too thick. If I keep on testing like this I'll run out of pellets soon T_T

19 (edited by tonycstech 2016-12-11 06:53:34)

Re: My Filastruder and Results so far! (ABS and PLA)

Are you extruding on to the floor or you use filawinder ?
YOu cant get perfect extrusion without filawinder.
PLA is softer then ABS when it comes out of the nozzle, so any force produced by bending the filament down the road, or the change in pulling the filament down (gravity) will mess with a diameter.
Thats why its so important to have CONTINUOUS curve of filament going to a winder.
See my filastruder review.
https://www.youtube.com/watch?v=sjmGWysUbn4
Watch entire video, you will learn allot.

Once you get consistent diameter (what ever it is) start dialing it up or down with the nozzle diameter.
Make sure barrel is insulated (stable temperature)
Make sure fan does not blow directly at the nozzle (stable temperature)

20 (edited by xXxOlivierxXx 2017-01-23 21:43:10)

Re: My Filastruder and Results so far! (ABS and PLA)

tonycstech wrote:

Are you extruding on to the floor or you use filawinder ?
YOu cant get perfect extrusion without filawinder.
PLA is softer then ABS when it comes out of the nozzle, so any force produced by bending the filament down the road, or the change in pulling the filament down (gravity) will mess with a diameter.
Thats why its so important to have CONTINUOUS curve of filament going to a winder.
See my filastruder review.
https://www.youtube.com/watch?v=sjmGWysUbn4
Watch entire video, you will learn allot.

Once you get consistent diameter (what ever it is) start dialing it up or down with the nozzle diameter.
Make sure barrel is insulated (stable temperature)
Make sure fan does not blow directly at the nozzle (stable temperature)

I do have a filawinder. I had already watched your filastruder review some time ago (I like your sense of humor btw) but I do not own a filastruder, I made my own extruder based on Lyman's design with a high torque wiper/windshield motor, a regulable motor speed controller, and a pid controlling a heating band. In summary, pretty much the same as a filastruder but I have more control over the settings involved on the extrusion process. I purchased the filawinder a couple of months ago hoping to get better filament tolerances and it did help a little, but it's still having troubles to find the sweet spot.
About insulating the barrel, I'm guilty of not having done this before. My local hardware store doesn't sell small pieces of fiberglass wool and I have been too lazy to go to another hardware store, I guess I'll get it this week and test again.

21 (edited by JeremyLGSiegfried 2017-01-24 01:06:23)

Re: My Filastruder and Results so far! (ABS and PLA)

See if they have rolls of foil-backed fiberglass wrap. It's supposed to be a "one-size-fits-all" solution when used with insulation tape.
I used this method after I destroyed the original "tube" on my Filastruder when I disassembled the barrel.

Filastruder 2607 w/ Filawinder @1.75mm.
Dual-extruder MaxMicron Prusa Mendel: RAMPS 1.4 w/ Repetier Firmware+Full Graphic LCD Controller, stock hotends, 3Dator extruders w/ MK8 gears, insulated enclosure w/ 2 heat lamps, RPi 2B+ w/ Repetier Server.
0.1-0.2mm layer height, heated bed w/ PEI surface, inductive-sensor autolevel, 0.5mm to 0.2mm nozzle diameters.

22

Re: My Filastruder and Results so far! (ABS and PLA)

JeremyLGSiegfried wrote:

See if they have rolls of foil-backed fiberglass wrap. It's supposed to be a "one-size-fits-all" solution when used with insulation tape.
I used this method after I destroyed the original "tube" on my Filastruder when I disassembled the barrel.

Yeah, I'll try that. They do sell rolls of fiberglass wool but only if you purchase the whole roll (which is sufficient to cover your entire ceeling) and I only need a small piece, which is the reason I have not purchased it yet. Something else I have noticed that is affecting my filament consistency, is that when a lot of pressure builds up on the tube, the motor tries to slow down a little, and that causes that alters the whole extrusion process. I'm thinking about purchasing a 1/3hp geared motor and adapt it to the extruder, that should be enough to keep the motor running consistently even with all the pressure built on the tube.