Designing a 3D Metal Printer / General Science and Electronics / Forums

Forums

4hv.org :: Forums :: General Science and Electronics

« Previous topic | Next topic »

Designing a 3D Metal Printer

1 2 3 next

Move Thread

LAN_403

Metalbot

Mon Jun 03 2013, 05:17PM

Registered Member #15261 Joined: Fri Apr 26 2013, 07:57AM
Location:
Posts: 5

Hi everyone...

I would like to discuss the pros/cons and engineering challenges facing the construction of a 3D printer capable of printing in metal.

I have created an open source initiative (linked to below) that aims to make a 3D Printer that can make parts in metal, there is quite a bit of information that has been amassed on the subject, so it is worth checking out...

From my experience, the two limiting factors with 3D printing have always been a - strength of the printed parts and b - part resolution. Hopefully it is possible to solve both of these problems by designing printer that works through a process called 'laser sintering' (although a few other avenues are being pursued).

Let me know what you think!

Best regards,

Jethro.

Carbon_Rod

Tue Jun 04 2013, 01:33AM

Registered Member #65 Joined: Thu Feb 09 2006, 06:43AM
Location:
Posts: 1155

Is this an ad or a question?

2Spoons

Tue Jun 04 2013, 04:45AM

Registered Member #2939 Joined: Fri Jun 25 2010, 04:25AM
Location:
Posts: 615

I reckon 'ad'. Still, no bad thing, given its for an open source initiative.

johnf

Tue Jun 04 2013, 07:25AM

Registered Member #230 Joined: Tue Feb 21 2006, 08:01PM
Location: Gracefield lower Hutt
Posts: 284

Why not buy a laser metal sinterer
I have had Ti6Al4V parts made that are incredible --and cheap
resolution on the machine that made my parts 32um at normal setting or 10um on the fine setting.
And as for strength no measurable difference between sintered and billet milled parts

Conundrum

Tue Jun 04 2013, 07:47AM

Registered Member #96 Joined: Thu Feb 09 2006, 05:37PM
Location: CI, Earth
Posts: 4062

I second that.

A water jet cutter is also viable, those are easy to rent and far more accurate than anything homemade.

If you are really determined to DIY it, low melt ie BiInSn alloy is known to be RepRappable and could then be copper or iron plated to increase the strength.

Should anyone make this work I propose that it be called the "Conundrum" 3D metal printing technique

-A

Adrenaline

Tue Jun 04 2013, 04:47PM

Registered Member #235 Joined: Wed Feb 22 2006, 04:59PM
Location:
Posts: 80

This isn't the real goal of the project, but another route:

You could RepRap a positive, x% bigger*.
Make a mold using the plastic part, too many undercuts would be troublesome, of course.
Then cast using of your metal of choice.

You could laser sinter using Polycaprolactone and do a lost wax casting too.

*account for metal shrinkage

Conundrum

Wed Jun 05 2013, 04:34AM

Registered Member #96 Joined: Thu Feb 09 2006, 05:37PM
Location: CI, Earth
Posts: 4062

Thats a good idea, appreciate the suggestion.
I will mention it to my friends over here with 3D printers..

Also, an interesting modification of PCL is to use granulated metal with a slightly higher melting point.
In this case the bismuth-tin alloy that melts at around 122C and include 0.2% powdered iron then induction pulse it to liquefy just the metal.
Voila, instant interconnects

Back in ze olden dayz we used to use cadmium alloys, but RoHS sent that the way of the velociraptor.
Probably a good thing too, Cd is nasty and not the best to have in a consumer product, about the only use other than light sensors is long duration batteries where Ni-Cd can tolerate extreme overdischarge that a NiMH or Li-ion would commit seppuku with extreme prejudice...

Carbon_Rod

Wed Jun 05 2013, 08:42AM

Registered Member #65 Joined: Thu Feb 09 2006, 06:43AM
Location:
Posts: 1155

I've done both bonded steel and nickel (under inert gas) hobby level processes. In general, the process created oxide voids/cracks from the metal itself, nonuniform bonding, and worse it is brittle. You are far better off casting a billet, and machining it to part tolerances.

This technology doesn't currently seem all that useful from a mechanical or electrical standpoint...
What do you plan to use it for?

Metalbot

Fri Jun 07 2013, 02:16PM

Registered Member #15261 Joined: Fri Apr 26 2013, 07:57AM
Location:
Posts: 5

Hi guys,

Why not buy a laser metal sinterer

The whole aim of the project is to make this technology more accessible, hence open source. Simply buying a machine will not do that, it's a grass roots movement ;) .

In any case a commercial base unit costs $500k<.

Just out of interest, what part did you have fabricated?

-

The process is called laser sintering and is far superior to filament deposition techniques used in the reprap. The benefits of choosing this route is that the resolution of printed parts are extremely good. That and all geometries are printable, overhangs and undercuts included. Also, no to minimal post processing is required. That is the whole point, it cuts out casting and firing.

The trouble comes in choosing an adequate laser that is affordable...

@Carbon Rod, where can I find more info about your setup? :)

This technology doesn't currently seem all that useful from a mechanical or electrical standpoint...

I have to strongly disagree... this is potentially revolutionary. Having the ability to print any geometry to high accuracy in strong metals such as aerospace titanium alloys will be very useful.

It opens up possibilities above and beyond milling or machining. Internal structures and complexity pose no problem for 3D this type of 3D printing. Complexity does not factor in the time or cost of making a part.

Carbon_Rod

Sat Jun 08 2013, 06:32AM

Registered Member #65 Joined: Thu Feb 09 2006, 06:43AM
Location:
Posts: 1155

"I have to strongly disagree... this is potentially revolutionary"
Metal injection molding (MIM) methods have already been tried by 4hv members over the years.

Evasiveness indicates this thread may be a simple social engineering attempt, and so I remain skeptical of your motivation.

My results were not that great, as the material was more like a useless spongy mess.

1 2 3 next

Moderator(s): Chris Russell, Noelle, Alex, Tesladownunder, Dave Marshall, Dave Billington, Bjørn, Steve Conner, Wolfram, Kizmo, Mads Barnkob