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Re: Filament Extruder - Convert pellets to filament

Sure, I can do that. It will be a faster and less frustrating assembly! Shoot me an email and we'll get it worked out.

227

Re: Filament Extruder - Convert pellets to filament

What kind of material are you using for the header wrap? I'm playing around with another idea but haven't been able to find decent insulation -- I've noticed it looks like the same stuff on the bottom of the bed of the Solidoodle. What's it called?

We've tried using some fiberglass type pipe insulation but it still seems to burn up (or a coating, not sure).

Thanks!

228

Re: Filament Extruder - Convert pellets to filament

jamesh wrote:

What kind of material are you using for the header wrap? I'm playing around with another idea but haven't been able to find decent insulation -- I've noticed it looks like the same stuff on the bottom of the bed of the Solidoodle. What's it called?

We've tried using some fiberglass type pipe insulation but it still seems to burn up (or a coating, not sure).

Thanks!

It's literally called header wrap:

http://www.amazon.com/High-Temperature- … B003RBF2OS

It's meant for wrapping exhaust headers on a car to keep heat away from other engine parts. I have leftovers from my other hobby - a turbocharged Nissan.

229

Re: Filament Extruder - Convert pellets to filament

Aha! I guess I just assumed you were calling the front end of the machine the header... cheers though that is exactly what I need! No more wasted heat!

Thanks!

230

Re: Filament Extruder - Convert pellets to filament

Destroyed thrust bearing...hopefully I will have the new one in by tomorrow.

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231

Re: Filament Extruder - Convert pellets to filament

DePartedPrinter wrote:

Destroyed thrust bearing...hopefully I will have the new one in by tomorrow.

Nice! I haven't thrashed one of those yet.

I think the reason these fail is that the faces of the shaft collar and the bushing in the flanges aren't parallel. Getting them parallel depends on getting the distance between flanges even, which is hard to do. I'm including spacers in the Beta v2, so this alignment is done consistently.

232

Re: Filament Extruder - Convert pellets to filament

Would a short, stiff spring work to even out any misalignment between the collar and flange?  Or is the force great enough to bottom out any spring that might go in there?

233 (edited by elmoret 2013-01-06 19:04:01)

Re: Filament Extruder - Convert pellets to filament

That's a great idea, and it has the benefit of letting me measure what that force is - if I know the spring coefficient, I can measure the loaded and unloaded length to find the thrust load. I'll order a variety from McMaster (they list spring coefficients), and let you guys know!

Edit: Just ordered some rated at 124lbs max load, which was the highest in a reasonable size. Part number: 9657K374

234

Re: Filament Extruder - Convert pellets to filament

From an email to Nickythegreek:

Make sure the faces of the bearing are as parallel as possible, by adjusting the nuts on the threaded rod. There should not be a gap between he bearing face and the shaft collar, or between the other bearing face and the threaded bushing. You can check this with a piece of paper when the machine is running and loaded. Try to slide the paper between the shaft collar and the bearing face. If it slides in, adjust the nuts to tighten that side a bit, or loosen the other side.

235

Re: Filament Extruder - Convert pellets to filament

I'm seeing about 20"/minute from the Beta v2 design. It is really spitting it out now!

236

Re: Filament Extruder - Convert pellets to filament

is their a chart any where that givel feet per pound on this diameter filiment

Ultimaker S3.

237 (edited by elmoret 2013-01-06 23:32:18)

Re: Filament Extruder - Convert pellets to filament

You can calculate it from the density of ABS-roughly 1g/cm^3. There's about 40000 centimeters in a 1kg roll. That's ~16000 inches. At 20 inches/minute, that's 13 hours per kg, or 5.89 hours per pound.

238

Re: Filament Extruder - Convert pellets to filament

5 gallon bucket did not work at all. It just ended up causing the filament to jump off the guide and bunch up.

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Re: Filament Extruder - Convert pellets to filament

nickythegreek wrote:

5 gallon bucket did not work at all. It just ended up causing the filament to jump off the guide and bunch up.


Yeah, that was my experience also. I've decided to just let it pile on the floor, for the time being.

I printed a spool (using filament from the filastruder) and loaded a pound (0.453kg) onto it:

https://dl.dropbox.com/u/1786359/Photo%20Jan%2006%2C%209%2043%2008%20PM.jpg

Total cost: $3, including electricity. (Plus a Filastruder and Solidoodle, of course!)

Feels good.

240

Re: Filament Extruder - Convert pellets to filament

I have parts on order for the filament spooler.  Unfortunately the motors and voltage regulators are coming from China and will be 3 weeks or so.  But by then someone will have figured out how to wire up Lyman's spooler with sensors, right?

At $150 for the kit, you have plenty of room for a spooler while staying under $250.  For the competition, you would need to design your own, but it would be necessary to have one.  Without controlling what happens to the filament after the nozzle, you can't guarantee the tolerance.  If the post extrusion cool end can insure the finished diameter no matter what happens at the other end, then that part gets a lot easier.

241 (edited by elmoret 2013-01-07 03:00:29)

Re: Filament Extruder - Convert pellets to filament

IanJohnson wrote:

I have parts on order for the filament spooler.  Unfortunately the motors and voltage regulators are coming from China and will be 3 weeks or so.  But by then someone will have figured out how to wire up Lyman's spooler with sensors, right?

I'm still not feeling in need of one. I let it pile on the floor, and I spool it with my drill. I spooled what's in the picture above in 30 seconds. I'm not sure it's worth the hassle and build time.

Ian: Have you had a chance to run it much more? Any thoughts/review? smile

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Re: Filament Extruder - Convert pellets to filament

I just started it up again tonight.  I marked a couple of points at the 1 minute and 3 minute marks so I can check the feed rate, but I don't want to measure until those points are on the floor.    The spooler would be convenient, but I feel like you need some definite control of the filament after extrusion to ensure consistent results for everyone.   Mine still wobbles quite a bit at the nozzle from the filament getting pushed around by the floor.

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Re: Filament Extruder - Convert pellets to filament

IanJohnson wrote:

The spooler would be convenient, but I feel like you need some definite control of the filament after extrusion to ensure consistent results for everyone.   Mine still wobbles quite a bit at the nozzle from the filament getting pushed around by the floor.

You're probably right. Most of my measurements have been +/- 0.04mm (Probably over 90%), but it is occasionally +/-0.08. Improving that would be good, so the spooler could be better over letting it flex from the floor, if the spooler can be controlled well.

244

Re: Filament Extruder - Convert pellets to filament

How far is everyone's filastruder from the floor?  I had a small table that would put the bottom of the platform 23" from the floor, but felt like I was having issues with the filament bending on the floor. I am now on a table that puts the bottom of the platform 29" and I feelt it is a bit better, but the filament is still getting some angles in it.

Just designed this little guy to clip onto the platform and help with guiding the filament, mine is falling off the brass/washers. I tried a brass eye hook at the end of the platform, but it did not perform well once the filament hit the floor.

http://f.cl.ly/items/1804202O102M1r1y3x3H/Photo%20Jan%2006,%2010%2000%2058%20PM.jpg

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245

Re: Filament Extruder - Convert pellets to filament

nickythegreek wrote:

How far is everyone's filastruder from the floor?

44" from floor to wooden base, in my case. It's on a high workbench.

246

Re: Filament Extruder - Convert pellets to filament

IanJohnson wrote:

I have parts on order for the filament spooler.  Unfortunately the motors and voltage regulators are coming from China and will be 3 weeks or so.  But by then someone will have figured out how to wire up Lyman's spooler with sensors, right?

At $150 for the kit, you have plenty of room for a spooler while staying under $250.  For the competition, you would need to design your own, but it would be necessary to have one.  Without controlling what happens to the filament after the nozzle, you can't guarantee the tolerance.  If the post extrusion cool end can insure the finished diameter no matter what happens at the other end, then that part gets a lot easier.

I have been thinking about an arduino with an ultrasonic transducer for the measuring and speed control and just having the filament come out over a thin sheet of something flexible that would not put too much resistance to the filament, with the transducer mounted below the sheet(pointing up) measuring the downward deflection and controlling the uptake reel to keep an even pace... sounds simple enough and cheap too <20$ for the electronics. I guess there would be quite a few optical ways to measure the filament droop too but this just seemed fairly simple and forgiving... I guess we will see smile

247

Re: Filament Extruder - Convert pellets to filament

I'm getting about 6" a minute.  What do you think the difference is with beta 2 that allows the higher speed?  Is it reduced turbulence from having an unbroken wall from hopper to nozzle?

248 (edited by elmoret 2013-01-07 05:51:17)

Re: Filament Extruder - Convert pellets to filament

IanJohnson wrote:

I'm getting about 6" a minute.  What do you think the difference is with beta 2 that allows the higher speed?  Is it reduced turbulence from having an unbroken wall from hopper to nozzle?

Yes, that's my thought. Beta 1 gave me 6"/minute as well. That's all that's really changed between them. Same auger, temperatures, melt zone, motor, etc.

Edit: Just spooled up another pound. The Filastruder is putting out filament faster than I can print spools! Also, after thinking about it, the auger model is the same, but it's not the same auger. I could have cut this one at a different angle, which would alter its efficiency.

249

Re: Filament Extruder - Convert pellets to filament

A while back you posted the McMaster part number for the 8" nipple - 44615K524

That one is welded.  Did it have a bead inside, was the auger able to go through smoothly?  They have a seamless nipple, but the wall is extra thick, Schedule 80 instead of 40.

250 (edited by elmoret 2013-01-07 05:53:43)

Re: Filament Extruder - Convert pellets to filament

That part number is the one I'm using on the Beta 2s. There's no seam inside. I can send you a retrofit kit if you'd like - I'm sending one to Jon.

The nipples on v1 are 44615K454 and 44615K464 - the 8" one is from the same product family.