76

Re: Filament Extruder - Convert pellets to filament

elmoret wrote:
DePartedPrinter wrote:
elmoret wrote:

Well, that answers that! Let me know what needs changed, or I'll play with it once I get my SD back up and running.


I had to bevel the edges so that the nuts could be turned. Also the pressure from the auger is probably going to destroy it fairly soon...the bottom of the sides are starting to split out.

This thing makes filament like crazy!

Ah- yeah, that makes sense. I might just make the whole thing shorter, to clear the nuts.

Did you print it solid? Splitting of the hopper is something I thought I avoided in this design. It was definitely an issue in precious hopper designs. Did you print it solid - 100% infill?

The current hopper I'd been using before I left on travel was a paper towel roll cut and taped. It seemed to work well, but is pretty crude.

Edit: Bummer that the wood split. I might have to move up a grade to get stuff with less knots.

You said it spits out filament like crazy? What temperatures? How many inches per minute?

I didn't print it solid. I should have.

I'm getting 8.5 inches per minute at 193. I haven't went much beyond that yet. 

Side note: contamination is really starting to clean up the more I run it.

SD2 with E3D, SD Press, Form 1+
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77

Re: Filament Extruder - Convert pellets to filament

Also, I can check the voltage on the motors once I am at work. My tools are all in my office.

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NYLON (taulman): http://www.soliforum.com/topic/466/nylon/

78

Re: Filament Extruder - Convert pellets to filament

DePartedPrinter wrote:

I didn't print it solid. I should have.

I'm getting 8.5 inches per minute at 193. I haven't went much beyond that yet. 

Side note: contamination is really starting to clean up the more I run it.

OK - Printing solid should help. I'll add that to the instructions.

8.5 inches/minute is about the average speed I used. I had trouble keeping anything over 12"/minute from kinking, because the filament doesn't have enough time to cool. I found 178-182 @6"/minute gave the best diameter tolerance on mine, but extruding at 195 and 9"/minute wasn't bad either.

Temperatures are probably going to vary a bit from unit to unit, thanks to measurement and thermocouple variations.

79

Re: Filament Extruder - Convert pellets to filament

elmoret wrote:
DePartedPrinter wrote:

I didn't print it solid. I should have.

I'm getting 8.5 inches per minute at 193. I haven't went much beyond that yet. 

Side note: contamination is really starting to clean up the more I run it.

OK - Printing solid should help. I'll add that to the instructions.

8.5 inches/minute is about the average speed I used. I had trouble keeping anything over 12"/minute from kinking, because the filament doesn't have enough time to cool. I found 178-182 @6"/minute gave the best diameter tolerance on mine, but extruding at 195 and 9"/minute wasn't bad either.

Temperatures are probably going to vary a bit from unit to unit, thanks to measurement and thermocouple variations.

Speaking of the instructions can you clarify what the white extension cord was supposed to be for? I did my own wiring job because I couldn't understand why you included that...

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80

Re: Filament Extruder - Convert pellets to filament

Also, the filament is extruding pretty much contaminate free now...took about 5 hours of run time.

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NYLON (taulman): http://www.soliforum.com/topic/466/nylon/

81 (edited by elmoret 2012-12-16 06:09:27)

Re: Filament Extruder - Convert pellets to filament

The white cord was to give you something to plug the AC adapter into. The idea was to have a single connection to the wall outlet, by cutting the white cord and using the female end.

The next power supply simplifies things, and doesn't use a plug. So that should be easier in future kits!

82

Re: Filament Extruder - Convert pellets to filament

DePartedPrinter wrote:

Also, the filament is extruding pretty much contaminate free now...took about 5 hours of run time.


Nice! Could have been burrs or filings that just took time to get pushed out.

I looked into putting a melt filter in, basically a piece of mesh filter/screen made out of stainless steel, right before the brass cap. McMaster sells screen with .3mm holes, but I haven't decided if its really needed.

Are you still running clear? Where'd you get the pellets from?

83

Re: Filament Extruder - Convert pellets to filament

elmoret wrote:

The white cord was to give you something to plug the AC adapter into. The idea was to have a single connection to the wall outlet, by cutting the white cord and using the female end.


That makes more sense now.

So any ideas on colorant? Cause I really want some tie-die filament.

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84

Re: Filament Extruder - Convert pellets to filament

Ha! Hmm. I've wanted to try food coloring, haven't yet though. I've also seen colorant on eBay, but haven't tried any.

Where'd you get your clear ABS?

85

Re: Filament Extruder - Convert pellets to filament

elmoret wrote:
DePartedPrinter wrote:

Also, the filament is extruding pretty much contaminate free now...took about 5 hours of run time.


Nice! Could have been burrs or filings that just took time to get pushed out.

I looked into putting a melt filter in, basically a piece of mesh filter/screen made out of stainless steel, right before the brass cap. McMaster sells screen with .3mm holes, but I haven't decided if its really needed.

Are you still running clear? Where'd you get the pellets from?

I got the clear from an old project with work. I haven't really printed much with it yet other than a simple test. I'll know on Monday how good it actually is.

SD2 with E3D, SD Press, Form 1+
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NYLON (taulman): http://www.soliforum.com/topic/466/nylon/

86

Re: Filament Extruder - Convert pellets to filament

It is going to be a problem getting specific colors in small quantities.

SD2 with E3D, SD Press, Form 1+
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NYLON (taulman): http://www.soliforum.com/topic/466/nylon/

87

Re: Filament Extruder - Convert pellets to filament

I've not received my kit yet: should I print the hopper and case, or should I wait until the dust settles and some new designs have evolved?

88

Re: Filament Extruder - Convert pellets to filament

I'd say wait. There's a fair bit to do before you need the hopper or case in assembly, and that way you get the latest designs for each. Although, they're both pretty cheap to print.

89

Re: Filament Extruder - Convert pellets to filament

I have done about ten hours of extrusion now. I want to go ahead and dissasemble to inspect the pipe nipples for wear. What is the best way to take this thing apart? Should it be warm to remove the auger? Do I need to extrude what is left in the auger first?

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NYLON (taulman): http://www.soliforum.com/topic/466/nylon/

90

Re: Filament Extruder - Convert pellets to filament

Yes, run it until nothing is coming out anymore, and while hot (over 180C) pull the motor and thrust bearing flange. The auger should slide out, and you can let it cool.

91

Re: Filament Extruder - Convert pellets to filament

elmoret wrote:

Yes, run it until nothing is coming out anymore, and while hot (over 180C) pull the motor and thrust bearing flange. The auger should slide out, and you can let it cool.


So I took the auger out and as you can see in the picture I am still getting some metal wear mixing in with the plastic. So my thoughts are that either the auger is slightly bent which is causing it to rub against the side of the nipple or the plastic is to abrasive against the internals.

If the auger is bent my only thoughts are that I could cut about an inch or so off of it and see what happens.  Other than that I think am going to switch to the stainless nipples (now I just need to find some that will work).

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92

Re: Filament Extruder - Convert pellets to filament

How close does the auger need to be to the brass plug for the machine to function?

SD2 with E3D, SD Press, Form 1+
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NYLON (taulman): http://www.soliforum.com/topic/466/nylon/

93

Re: Filament Extruder - Convert pellets to filament

Hmm. It's kind of hard to see on my phone, but that does look pretty bad. I used to get one spec every 20-30 feet.

It's possible the auger got bent when I cut it. You could cut it two inches shorter, and slide the thrust bearing flange in as far as it will go. You will probably need the assembly to be hot to put the auger in.

94

Re: Filament Extruder - Convert pellets to filament

DePartedPrinter wrote:

How close does the auger need to be to the brass plug for the machine to function?

I've only tried it with the end of the auger 1" from the brass. I'd imagine it would work as long as you had auger throughout the 4" nipple. Something I've been meaning to try!

95 (edited by nickythegreek 2012-12-16 22:23:35)

Re: Filament Extruder - Convert pellets to filament

Whenver I slice the hopper in slic3r, it looks like it is not keeping the hopper hollow.  I have this same issue when I try to cut the companion cube storage box on thingiverse.  Am I missing a setting somewhere?

http://www.soliforum.com/misc.php?action=pun_attachment&item=653&download=1

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96

Re: Filament Extruder - Convert pellets to filament

I've seen Slic3r 097 throw in a couple of solid layers at random.  Try 093 and see what happens.

97 (edited by nickythegreek 2012-12-16 22:59:29)

Re: Filament Extruder - Convert pellets to filament

Got the electronics enclosure printed out.

slic3r .3mm, 3 shells, 20% infill, glass bed + hairpray, octave glow in the dark white/green (first print with this filament). This is the longest horizontal surface i've printed yet.

The front left and back right corners lifted a fair amount and I got 2 corners cracks on one of the side. Does the fan mod help with this?

Totally useable though!

http://www.soliforum.com/misc.php?action=pun_attachment&item=654&download=0

http://www.soliforum.com/misc.php?action=pun_attachment&item=655&download=0

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98 (edited by DePartedPrinter 2012-12-16 23:37:12)

Re: Filament Extruder - Convert pellets to filament

nickythegreek wrote:

Got the electronics enclosure printed out.

slic3r .3mm, 3 shells, 20% infill, glass bed + hairpray, octave glow in the dark white/green (first print with this filament). This is the longest horizontal surface i've printed yet.

The front left and back right corners lifted a fair amount and I got 2 corners cracks on one of the side. Does the fan mod help with this?

Totally useable though!

http://www.soliforum.com/misc.php?action=pun_attachment&item=654&download=0

http://www.soliforum.com/misc.php?action=pun_attachment&item=655&download=0


Mine ended up warping on the top as well. You'll have to cut some openings if you want things to fit (I recommend a bench grinder)

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99

Re: Filament Extruder - Convert pellets to filament

elmoret wrote:

Hmm. It's kind of hard to see on my phone, but that does look pretty bad. I used to get one spec every 20-30 feet.

It's possible the auger got bent when I cut it. You could cut it two inches shorter, and slide the thrust bearing flange in as far as it will go. You will probably need the assembly to be hot to put the auger in.


I cut off two inches and cleaned up the auger with a wire brush while I was at it. I noticed that there is some scoring (see picture) right where it would have lined up with the end of one of the pipe nipples. This also occurred on the end closer to the motor where it met the end of the pipe nipple. 

I guess this could have to do with how well the motor was lined up with the bit...guess we won't need to go to stainless since the shavings are obviously not coming from the pipe nipples.

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100

Re: Filament Extruder - Convert pellets to filament

I forgot to mention! The pipe nipples have little lips on their ends, on the inside edge at each end. I removed these lips with a dremel, so the entrance is smooth. Definitely will add to the instructions, sorry!