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We get to check plenty of actually cool filaments and check out a bunch of various printers at MatterHackers. Over the previous yr, the variety of out there filaments has skyrocketed as has the variety of out there printers and printer choices. Sadly, the quantity of obtainable details about all of those choices leaves a lot to be desired.
On high of questions on numerous filaments, we get plenty of questions on twin extrusion.
Do I want twin extrusion? What sorts of issues can I print with twin extrusion? Is twin extrusion higher than single?
We love sensible purposes of 3D printing, so we thought it could be good to highlight 2 newer filaments in addition to twin extrusion printing by designing and printing upgrades for an older printer.
We now have an outdated KitTaz (Taz 3), by Lulzbot, from 2013/2014 that has seen fairly a little bit of use. The plastic linear bearings developed a little bit of play, and it wanted an overhaul.
Supplies
The IGUS tribo-filament was designed to print bearings and different elements that require low friction or low abrasion properties. In case you’ve ever used IGUS parts for different initiatives, you recognize they make prime quality parts, and their filament isn’t any exception. It prints simply, cleanly, and has remarkably low friction for a 3D printed half.
Since IGUS focuses on bearings, linear rails, and different associated {hardware}, we figured it made sense to make use of IGUS filament to print replacements. It’s additionally an ideal solution to highlight their filament to indicate what it will probably do.
We wanted to interchange the next:
- 4 single linear bearings (SLB) for heated mattress (Y axis)
- 1 single linear bearing for X carriage
- 1 double linear bearing (DLB) for X carriage
- 2 double linear bearings for Z axis mounts
I shortly mocked up a bearing that matched the inventory SLB and printed it out of the Tribo filament to verify match and performance.
It got here out fairly properly for a primary print. The middle gap was a bit sloppy so there was a little bit of play, nevertheless it confirmed that this materials would work to be used as a bearing. There have been a couple of issues we observed whereas wanting on the printed SLB.
The Tribo glides on the sleek rods very easily and quietly, nevertheless it will get soiled shortly and it doesn’t appear as robust/sturdy because the ABS that the inventory elements have been printed in. The soiled half is solely a beauty problem and never a giant deal, however we wished our Taz to nonetheless look good after the upgrades. The sturdiness is clearly a problem. We don’t need these printed substitute elements to interrupt anytime quickly. Additionally, the Tribo filament is on the costly aspect of filaments. For the reason that solely half we’d like the Tribo for is the half contacting the sleek rods, we will print the housings out of one other materials.
The inventory Taz items have been printed in ABS. Whereas ABS is a flexible and helpful filament, it tends to warp, and that’s not ultimate when printing issues like bearings with tight tolerances. We determined to make use of PETG for the outer housings. PETG is straightforward to print, has just about no warp, and is about as robust, if not stronger, than ABS. It additionally has a pleasant shiny floor end. There are a couple of totally different PETG filament choices out there – MatterHackers PETG and MadeSolid PET+ are the 2 we print with most frequently for useful elements. Printing temps could very barely, however 240-260C with a heated mattress at 50-60C is acceptable the vary. For this mission, we used the MadeSolid PET+ in opaque black with a view to match the unique printed elements.
Twin Extrusion
The inventory SLB has a printed housing, after which a bearing is slid in or pressed into the housing. With twin extrusion we will simply mannequin the outer housing and internal bearing and print it out at one time with two totally different supplies.
There are other ways to mannequin elements for twin extrusion, however 2 separate STLs are required. I exploit Solidworks for many of my modeling. The best manner I’ve discovered for elements like that is to mannequin the half in a single half file, however to not merge all the strong our bodies in order that I can save them as particular person STL information. By modeling the elements in a single file as separate strong our bodies, each elements are aligned in the identical Cartesian area which permits for straightforward alignment of the STLs in MatterControl.
The gray portion might be printed in PETG. The crimson sleeve might be printed within the IGUS tribo-filament.
As a result of the our bodies weren’t merged I can cover one or the opposite and export the seen half as an STL.
Subsequent, I convey the STLs into MatterControl. I like to simply drag one of many elements into the queue, after which drag the opposite half instantly into the 3D View window.
When utilizing twin extrusion, the colour of the elements within the 3D View panel signifies the extruder that might be used to print every half. As proven, each of those elements can be printed in the identical materials by Extruder 1.
For this setup, PETG is Extruder 1 and the IGUS filament is Extruder 2. We wish the sleeve printed in IGUS, so we choose the bearing sleeve, then choose the Materials drop down bar on the proper aspect of MatterControl.
We then choose the suitable extruder.
The colour of the half within the 3D View will change to point that the elements are printed with totally different extruders.
Now, we have to align the elements. Since we modeled them collectively, all we have to do is choose “Align”
Now the sleeve is correctly aligned contained in the housing. Save our adjustments and we’re nearly able to print.
From our check printing with the IGUS filament, we found that it has pretty low viscosity when at printing temp, so it’s susceptible to a good bit of oozing. When twin extruding, oozing is usually a problem with the extruder not at the moment in use. There are a couple of methods to fight this. For the bearing print, we’re going to make use of a Wipe Tower.
Wipe Tower is barely seen within the Superior view mode. It’s below Settings > Normal > A number of Extruders.
The wipe tower is a strong block of filament printed off to the aspect of the printed half that enables every extruder to prime and wipe earlier than starting the following layer. We simply must specify the dimensions of the tower. Coming into 10mm within the setting will make the wipe tower 10mm x 10mm and it’ll print as tall because the printed half. The wipe tower doesn’t present up within the 3D view, however we will take a look at it within the Layer View window.
The wipe tower will alternate between extruder 1 & 2 which helps each prime the nozzles in addition to get rid of some stringing/oozing from the precise printed half. On this picture, the black strains are extruder 1 and the teal strains are extruder 2.
The MakeIt Professional was used to print. We used coarse high quality settings – .3mm layer peak – primarily to get the half printed shortly to check – they usually nonetheless got here out properly on the primary attempt.
There are a couple of areas the place the Tribo filament bled into the PETG and vice versa. However this was fairly minimal and should not have any impact on the perform of the half. The printed model is kind of a bit smaller in measurement and weight than the inventory model with the pressed-in bearing. Whereas this doesn’t actually have an effect on the efficiency in any vital manner, we’re all the time a fan of constructing issues extra compact and environment friendly.
As you’ll be able to see within the video under, the bearing works nice. The printed bearing can also be fairly a bit quieter than the inventory bearing.
We’d name {that a} success! We needed to alter the scale a bit to get the precise match we have been in search of – as little play as attainable whereas permitting free motion alongside the sleek rod – however the finish outcomes have been wonderful.
We’re not executed, although. Whereas we’re very proud of the twin extrusion outcomes, we additionally wished to indicate how you should use 2 supplies on a component with out utilizing a twin extrusion 3D printer.
We modified the mannequin a bit in order that we will print the outer housing and the internal sleeve individually, and press them collectively.
Whereas it requires 2 separate print jobs, it has a couple of advantages over printing in a single piece.
First, the prints are a lot cleaner. As a result of we’re simply utilizing 1 nozzle, oozing/stringing isn’t a problem. Second, it took us a couple of iterations with the twin extrusion to get the internal diameter of the bearing to suit completely. The primary ones had a little bit of play and the twond model was a bit tight. It’s a lot faster and simpler to print the internal sleeve, check the match, after which alter accordingly than it’s to must print the entire bearing meeting.
Lastly, and most necessary to us for this mission, printing them individually makes the elements modular and extra simply replaceable. If the internal sleeve begins to develop some play, we will simply print a brand new sleeve and change it reasonably than having to print a complete new bearing meeting.
We printed out all of the bearings and put in them on the machine.
X carriage – double linear bearing on high rail, single on backside rail
Y-axis single bearings mounted to the mattress plate
Z-axis double bearing
We’re very proud of the outcomes. The printer strikes smoother, has much less play, and is noticeably quieter with the brand new bearings put in. The IGUS filament works superbly as linear bearing materials, and the PETG is powerful, sturdy, and has a clear, shiny floor end. It’s an incredible mixture.
We’ve made our designs – each the twin and single extrusion variations – out there for obtain. They’ll work on any Taz 3/KitTaz, Taz 4, or Taz 5. The Taz 5 doesn’t use the identical Z-axis bearings, however the X and Y axis bearings are the identical. Print ‘em out, improve your machine, and ship us footage!
Together with the bearing upgrades, we additionally upgraded the electronics to an Azteeg X3 Professional with a Viki2 LCD show, and added the Kraken quad sizzling finish, by E3D. Search for all these particulars and a few quad extrusion craziness within the subsequent characteristic article.
Thanks for studying. Questions and feedback are all the time welcome and, as all the time,
Comfortable Printing!
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