Engineering Updates – Thermocouples, Hot Ends, and 3D Printing Research

This is called the “Engineering” Update, but it’s really a reflection of all the work going on at re:3D – engineering, R&D, customer service, operations and everyone else included. As our company ethos begins, “We are a team…”, and that team has been working hard to solve problems for our customers, improve the performance of our products and contribute to the body of knowledge within our additive manufacturing industry. Here are a few snapshots of what’s been happening at re:3D since our last post.

The Gigabot FFF (Filament) Platform

MCU Thermocouple Errors

For the past couple of years, an intermittent problem would pop up on the Gigabot 4 (and GigabotX 2) printers related to the thermocouples. Sometimes the printer would throw an “MCU shutdown: Thermocouple reader error” fault during the bootup cycle (Figure 1). There were some arcane incantations that could be performed to sometimes clear the fault in any given instance, but ultimately, better grounding of the extruder seemed to solve the problem. Recently the error started showing up again, potentially delaying product shipments. So the engineering team put intense focus on investigating the cause of the error.

Figure 1: “MCU Shutdown” error thrown by Klipper due to a fault registered on the MAX31856 thermocouple chip.

re:3D’s uses the Archimajor 3D printer motherboard from US manufacturer UltiMachine (South Pittsburg, Tennessee). The Archim boards use a MAX31856 chip from Maxim Integrated to amplify and digitize the input signals from the thermocouples, and it was this chip that was throwing the pesky error. Buried in an obscure Maxim FAQ was a cryptic comment about shunting the negative lead of the thermocouple input to ground to improve performance. The engineering team tried it out (Figure 2), and this has reliably prevented the error from occurring. re:3D now has a field-fix available for service technicians to use when encountering this issue on customer machines and is also working with UltiMachine to incorporate this feature into future versions of the motherboard.

Figure 2: Shunt resistors installed on the thermocouple inputs.

Terabot Hot End Conversion

re:3D has a long history of designing and testing extruders and hot ends, always looking for ways to push more plastic to print faster. (OG members of the re:3D community might remember the early “Mondo” hot end prototype.) To keep up with its larger build volume (915 x 915 x 1000mm), re:3D’s Terabot filament printers have been shipping with “20 Series” hot ends, which have a larger heater block to increase the residence time of the plastic within the heat zone and speed the melting process (Figure 3). However, testing has shown that with the proper slicer and configuration settings, re:3D’s standard hot ends perform equally well and are less prone to occasional inconsistent flow or leaking at the nozzle.

To improve overall performance and reliability, Terabots will now be supplied with standard hot ends. This is a minor engineering change, and the Customer Service team has developed a simple and easy-to-install upgrade kit that requires no major modifications to existing Terabot platforms. The Customer Service team is looking for initial Beta Testers for the Terabot hot end conversion kits. If you are interested, you can read more about re:3D’s Beta Testing Program below.

re3D Engineering Blog post update April - Std Hot End
re3D Engineering Blog post update April - Series 20
Figure 3: Comparison of 20 Series hot ends (a) and standard hot ends (b) installed on a Terabot.

The GigabotX FGF (Pellet) Platform

There has been progress on both GBX part cooling and GBX bed mesh compensation, but the Gigaboss leading those efforts is busy finishing his master’s thesis, so you’ll have to hold off until next time for a written update. Do worry – it’ll be worth the wait.

Software Improvements

re:Bugger

This spring semester, re:3D has been pleased to host Yasseen Hilal, who is studying computer science at the University of Texas, as a software engineering intern. Yasseen took on the task of developing a printer debugging tool for use in the field. The re:Bugger (Figure 4) simply plugs into a Gigabot 4, Terabot 4 or GigabotX 2 via a network cable, then through a simple and intuitive interface reads the available log files to detect errors and provide possible solutions. Log files and performance graphs can be easily exported from the printer onto a USB drive for later review, and the re:Bugger also allows users to flash the latest printer firmware onto the Raspberry Pi without needing network access. This all helps reduce printer downtime.

Yasseen did a great job on his project, and the re:3D team wishes him all the best on his future endeavours.

Figure 4: The re:Bugger printer debugging tool.

Bed Mesh Compensation

There was recent feedback on accuracy and standard operation being manually intensive. Updates have since been made on the mesh compensation workflow which will now carry out a startup procedure to automatically calibrate the Z offset, tram the Z lead screws, and adaptively probe only the area where the part is printing.

This new workflow is meant to keep manual efforts to a minimum during calibration. This procedure is written into Klipper as a comprehensive macro and can be called at the beginning of a print using a single line of Gcode in the slicer.
This master macro approach makes usage simple for the end user while also ensuring accurate and standardized results. There are also optional advanced parameters for users who want to fine tune and experiment with values.

  • Procedures:
  • Prime the extruder
  • Clean the nozzle for accurate offset calibration and probing
  • Model calibration
  • Z offset Calibration
  • Z tilt calibration
  • Adaptive probing

We are actively seeking feedback through our beta testing program, and encourage new testers to contribute their insights to further refine and improve this workflow. You can learn more about re:3D’s Beat Tester Program below.

HELM

Work also continues on HELM, the printer fleet management software under development at re:3D. There have been some minor changes under the hood since the last update, but the most obvious improvement is the user interface – it’s cleaner and easier for casual operators to use (Figure 5). This is an open-source project, and you can try the application yourself, report problems, contribute, or follow progress here: Helm on GitHub.

Figure 5: Comparison of the HELM GUIs - older version on top, updated version on bottom.

Beta Testing Programs

As an open source company, re:3D celebrates collaboration with our community of users, customers and vendors. Historically, select new changes or features were offered to existing customers for ‘beta testing’ as part of re:3D’s internal engineering process. The Beta Testing Program has since evolved and become more formalized with contributions from engineering, customer service and sales and marketing. An application form is now available on the re:3D website here where you can apply to be a beta tester through the following steps:

1. Choose Your Desired Beta Product/Software

Read a short summary of available beta products with how it will improve the Gigabot user experience. Ideally, applicants will have non-modified printers so that the performance improvements of the beta products can be accurately assessed.

2. Sign Up

Fill out a Google Form to express your interest in beta testing the selected product for which you’d like to be considered.

3. Confirm Acceptance

A notification email will be sent to confirm your selection as a beta tester. This will include a beta tester release agreement, a defined testing period, steps on how to submit feedback, and a link to the Forum for updates on these products. Invoicing and delivery information will also be requested, then the beta products will be shipped.

4. Begin Testing

An Instructional Guide with detailed installation instructions and troubleshooting tips will be provided with the beta products.

A Google Form will be sent to beta testers no less than monthly for each product to solicit feedback and recommendations.

5. Be a proud GigaTester!

For now, there are two beta test products available for consideration:

  • Bed Mesh Compensation (Gigabot 4 only)
  • Terabot Hot End Conversion (Terabot family)

Watch for these additional beta testing opportunities in the coming weeks:

  • Bed Mesh Compensation (GigabotX 2 only)
  • Feedstock Crammer (GigabotX family)
  • 1.75mm Filament Conversion Kit (Gigabot / Terabot family)
  • GBX Part Cooling (GigabotX family)

R&D Programs

Though there has been recent turmoil and uncertainty in the news about federal research grants, re:3D continues to support R&D contracts for the Department of Defense (DOD), NASA, the Department of Energy (DOE) and the National Science Foundation (NSF). Some of those projects went along on re:3D’s recent trip to Hawai’i, but the others have been making progress too!

ReCreateIt (NSF)

ReCreateIt is a multinational initiative led by re:3D, with a goal to transform waste plastic into valuable products through 3D-printing and community-led design. To achieve this mission, re:3D is collaborating with the Austin Habitat for Humanity ReStore, where a Gigalab was designed and delivered in December 2024. Since its delivery, the Gigalab has been outfitted with a granulator, pellet/flake dryer, a GBX2 XLT, all necessary mechanical and electrical tools, and personal protective equipment. The long-term goals of the ReCreateIt Gigalab is to recycle and reuse over 10,000 lbs of local plastic waste over its lifetime while being a net-zero energy manufacturing lab.

Compared to other Gigalabs, the ReCreateIt Gigalab will feature various additional sensors that monitor temperature, humidity, emissions, particulate matter, and energy usage. The sensors will allow the team to construct a comprehensive model of the Gigalab system and quantitatively assess the environmental impact of the Gigalab and the recycling efforts. This data may also provide the re:3D team with insights that may spur redesigns and improvements of future Gigalabs towards more energy-efficient and sustainable systems.

To support daily operations, three Gigalab associates have joined the team to collect and sort incoming waste plastics, and to operate the machinery that processes and prints with the recycled materials. The re:3D team is actively mentoring the associates to enable them to operate and troubleshoot the Gigalab equipment safely and autonomously (Figure 6).

Figure 6: Gigalab associates celebrating the first print of the ReCreateIt Gigalab!

There have also been advancements in 3D printing with recycled polypropylene (PP) — the second most used commodity plastic in the world. In fact, the vases shown in Figure 7 below are printed from 100% recycled PP, which were originally storage bins collected at the ReStore that were destined for the landfill. While there still are challenges to scale up into furniture pieces such as end tables or stools, achieving successful and functional parts using 100% recycled material, without any additives or blending agents, is a significant milestone in sustainable manufacturing.

Figure 7: Vases printed from 100% recycled polypropylene (PP).

To showcase the progress on the project to the public and local media, the ReStore and re:3D teams co-hosted a soft opening at the ReStore on April 19. Well over a hundred curious customers stopped by to take a look at a large array of printed parts made from recycled materials. Attendees were invited to share their ideas for future products, offer feedback on existing prints, and learn more about the environmental and social impact of the initiative. The majority of visitors also expressed major interest in the behind-the-scenes of the project and participated in tours of the Gigalab, where they got a first hand look at the recycling and manufacturing process including the GBX2 in motion.

re3D Engineering Blog post update April - Convergence Soft Opening 4
re3D Engineering Blog post update April - Convergence Soft Opening 3
re3D Engineering Blog post update April - Convergence Soft Opening 2
re3D Engineering Blog post update April - Convergence Soft Opening 1
Figure 8: ReCreateIt Soft Opening at the AHFH ReStore.

If you’re in the Austin area, stop by the ReStore at 500 W. Ben White Blvd where you can check out the prints in person, buy a piece printed from recycled waste and directly participate in the circular economy yourself.

“Bigger, Better, Faster” FGF (DOD/US Army)

The large FGF printer being developed under a US Army SBIR R&D award has come a long way since the last update. The frame is complete, and the linear motion components – including ball screw actuators and servo motors – are installed and commissioned (Figure 9(a&b)). Another major change from re:3D’s traditional build style is the use of a separate HMI (human-machine interface) and control pedestal (Figure 9(a&c)), rather than having an electrical box and touchscreen interface mounted directly to the printer’s frame. Not only does this change allow for the room needed for added servo motor controllers and power supplies, it makes the electrical and control components more accessible for service. Having a full computer built into the HMI pedestal will allow users to access third-party software when necessary for servo motor diagnostics, along with providing opportunities for performing CAD and slicing tasks at the same workstation as the printer operation, without requiring network access – which is not available or desirable in some situations.

re3D Engineering Blog post update April - army sequential_a
re3D Engineering Blog post update April - army sequential _ b
re3D Engineering Blog post update April - army sequential_c
Figure 9: Printer frame with HMI/control pedestal (a); extruder mounted on z-axis actuator with temporary side hopper (b); inside view of HMI/control pedestal during initial wiring (c).

After commissioning and initial tuning, the printer’s extruder was finally tested. This is a novel and exciting new design from Dr. David Kazmer’s group at the University of Massachusetts Lowell, who are collaborating with re:3D on this effort. After a few hiccups caused PLA to thermally degrade inside the barrel, DynaPurge became the first material extruded through this system. As shown in Figure 10, the first extrusion looks like – well, you know. But it’s a first extrusion nonetheless, and the team is excited for the rapid progress of this project.

Figure 10: First extrusion! No judgments, please.

Additively Manufactured Thermal Protection Systems (NASA)

re:3D’s R&D team designed and built a 5-axis printer to deposit ablative foam materials onto non-planar surfaces. This has been done before using robotic arms, but this is a unique design based on a gantry system, intended to investigate the economy of a different kinematic approach to conformal printing. The frame and x, y and z axes systems are similar to re:3D’s Terabot printer. But to add the extra degrees of freedom, the extruder (a ViscoTec volumetric deposition pump) rotates about the Y-axis, and the whole bridge rail rotates about the X-axis (Figure 11(a&b)).

re3D Engineering Blog post update April - AMTPS axes _a_
re3D Engineering Blog post update April - AMTPS axes _b_
Figure 11: AMTPS printer axes definitions (a) and motor locations (b).

Rather than adapt the Archimajor motherboard for 5-axis control, re:3D collaborated with the Siemens team at the Charlotte Advanced Technology Collaboration Hub (CATCH) to implement an advanced industrial control system. The CATCH team helped identify appropriate servo motors and control hardware for the printer, and also provided training both at a partner solution provider’s site in Houston and at their own Machine Tools facility in Elk Grove Village, Illinois.

For the final touches and commissioning of the printer, the system was sent to Bobby Cole and his team at Think-PLC in Lexington, North Carolina. Think-PLC is a Siemens Solution Partner, and Bobby is highly regarded in the world of industrial controls and automation for his work with machine builders and manufacturers, and re:3D’s experience bears this out. Think-PLC identified and corrected some deficiencies in the AMTPS printer after they received it, then worked to understand the system requirements and implement control kinematics to achieve optimal performance within the limitations of the printer’s mechanical design. It has been great working with them and watching the printer come to life (Figure 12). The AMTPS printer will soon be returning to re:3D in Austin for the installation of the deposition system and the beginning of print testing.

Figure 12: AMTPS printer demonstrating a range of kinematic motion at Think-PLC’s facility in North Carolina. (Credit: Think-PLC)

Another collaborator on this project is Addiguru, a software company that specializes in in-situ monitoring technologies for additive manufacturing processes. While re:3D is designing a mounting system for multiple cameras to monitor the deposition of the TPS foam onto the substrate (Figure 13), Addiguru is developing the software to measure the width of the extrusion and flag excessive variances in volumetric deposition in real time. Although it won’t be implemented within the scope of this effort, future work on this project could incorporate Addiguru’s software to provide feedback into the Siemens system for closed-loop control of the deposition process.

Figure 13: Three-camera mount system providing full video coverage of the ViscoTek deposition nozzle.

Water Bottle Granulation (DOE)

The collaboration with Oak Ridge National Laboratory (ORNL) continues with a focus on separating the recycled PET (rPET) flake from granulated water bottles out of the flake/water slurry coming from the granulator. ORNL is procuring a hydrocyclone for the separation step. Hydrocyclones produce opposing vortices within a chamber which force large, heavy particles out through a reject port and lift lighter fines and liquid out through the overflow. The physics of hydrocyclones is quite interesting and watching YouTube videos about them can easily burn a couple of hours from your day.

Once the rPET flake is separated from the water it must be dried, and re:3D has been studying the efficacy of desiccant drying on wet flake. A sample of granulated water bottles was soaked in water overnight, then dried in an industrial recirculating desiccant dryer at 70°C. The moisture content of the flake was measured using gravimetric analysis (i.e., loss on drying) at multiple steps throughout the process. As shown in Figure 14, as little as three hours is required to dry the flake back to its original, equilibrium condition, and an additional three hours may be sufficient to dry the flake sufficiently for immediate extrusion processing (below 200 PPM). These results are consistent with re:3D’s previous tests on “Drying rPET Water Bottle Flake”.

Figure 14: rPET flake moisture content measured throughout a water soaking and drying process.

It’s a bit of a chore to collect, edit and format the information and photos telling re:3D’s behind-the-scenes technical stories, but it’s also incredibly fulfilling to be able to share the good work going on here and appreciate the cool factor in what we get to do every day. All in all, it’s worth the time.

Thanks for reading along, and as always… Happy Printing!

Patrick, Chris, Mitchell, Taylor

Blog Post Authors

A Year of #FreePrintFriday Open-source Designs by re:3D

When we set up the Gigalab in Bayamón, Puerto Rico, alongside our neighbors and partners at Engine-4 Foundation, we weren’t just building a container lab. We were planting a seed, an idea that digital fabrication should be for everyone, and that creative tools should serve the people around us.

So we started small. One design, every Friday. Free. Useful. Sometimes funny. Sometimes experimental. Always open.

What started as a small weekly gesture quickly grew into something bigger, a rolling catalog of open-source designs, community responses, and whimsical one-offs that anyone can download, print, and build on. While we’ll be highlighting a few of our favorite moments here, there are plenty more where these came from. So if something catches your eye, or if you’re just curious, we invite you to dive into the rest of our #FreePrintFriday designs on Thingiverse and Cults3D.

Big Bots, Big Ideas

Interior of 3D printing Gigalab

Inside the Gigalab, we’ve also been putting our large-format GigabotX printers to work. Many of our favorite designs showcase how recycled plastic and local fabrication can do so much more:

The Flowform Stool

3D printed stool
Printed in one piece, strong enough to sit on, weird enough to get compliments.

Lumina Astra Lamp

3D printed hexagonal ceiling lamp shade
Dodecahedron inspired light fixture, sharp and stylish for any space.

Extension Cable Wrap

3D printed cable wrap with red cable wrapped around
A functional form made to tidy up heavy-duty cords on the go.

Manta G1

3D printed kite flying in the sky

Our 3D printable kite experiment. Still very much a work in progress, but easily one of the most fun things we’ve ever designed. Building something that’s meant to flex, fly, and occasionally crash (gracefully) has pushed us to think differently about material use, weight, and structure—all while showcasing the beauty of recycled 3D printing.

Collaborations with Our Local Community

Working alongside our neighbors at Engine-4 Foundation has been core to Gigalab’s mission. Many of the ideas we’ve printed came directly from conversations at Engine-4 with Co-Founder, Luis Torres, whether it was a passing comment, a workshop brainstorm, or someone pointing at a problem and asking, “Can we 3D print a fix for that?”

Some standout collabs include:

Hydro Rocket

3D printed hydroponic rocket shaped container
A modular hydroponic tower, designed to help promote urban agriculture in small spaces, printed with reclaimed plastic.

Garden Picker

3D printed weed fork picker
handy garden picker, born out of a brainstorm about accessible harvesting tools for local growers using formbot, the bot doesn't do everything (yet).

Drone Care Package Adaptor

3D printed drone adapter holding a net with a package

The drone care package hook, a collaboration with both Engine-4 Foundation and the Municipio of Bayamón, used in earthquake simulations to deliver supplies via agricultural drones.

More on the simulation from Puerto Rican local news:
Primera Hora | Telemundo

These kinds of projects remind us that when we design with our community, we design with purpose.

Culture, Celebrated in Layers

Some of my proudest open-source designs that connect with my Puertorrican identity:

Artificial Coqui

3D printed frog
A tiny homage to Puerto Rico’s most iconic Coquí frog.

Three Kings ornament

3D printed sculptures of three kings
A Low Poly Three Kings Ornament, blending modern design with beloved holiday tradition.

Monumento al Jíbaro Puertorriqueño

3D printed model of statue Monumento al Jibaro Puertorriqueño

Our photogrammetry model of the Monumento al Jíbaro Puertorriqueño, scanned, modeled, and shared to honor Puerto Rican heritage in a tangible way.

These designs always spark conversation, everything from an “aw” to an “I want one” to someone recognizing their own story in it, saying, “I used to drive past that monument every day. The view was breathtaking.”

Designed for People

Girl with her 3D printed red prosthetic leg cover

The most personal of our projects came through the Rotationplasty Prosthetic leg shell designs.

It started with a visit. Wilfredo Rodriguez and his daughter Emily came to Engine-4 with a bold question: could we design something that didn’t just cover for her unique rotationplasty prosthetic leg, but make it look and feel amazing? Something Emily could wear with confidence, something that felt like hers.

We scanned her leg using photogrammetry, modeled around it with Rhino and Fusion 360, and started prototyping with rPETG, Nylon, and TPU. Eventually, we found the right balance, lightweight, flexible, and durable enough for everyday life. The final shell was finished with automotive-grade paint for a smooth, protective finish.

But the story didn’t stop there.

Girls with their 3D printed red and white prosthetic cover

Left is the back of Emily’s cover, middle is daniels cover and right is Emely and Anya
Emily’s friends Anya and Daniel, all the way in Boston, got scanned too. We designed and printed their custom shells right here at the Gigalab in Puerto Rico, and sent them north, each one uniquely shaped and styled for them.
This wasn’t just about aesthetics. It was about saying, with a smile, “I want that leg”

Creative Chaos at Haystack

group of people meeting for 3D printing event

Located on the rugged coast of Deer Isle, Maine, Haystack Mountain School of Craft is a legendary space where artists, designers, and thinkers come together to push creative boundaries. We were lucky enough to be invited to spend a week there with the GigabotX 2 XLT for Haystack Labs, joining a wild mix of tinkerers and craftspeople for a creative tech residency.

re3D Haystack_1
re3D Haystack_3
re3D Haystack_2
Designed by Shelby Doyle and printed on GBX2 XLT

At Haystack, we experimented with University of Maine’s wood pulp PLA feedstock, tested out sculptural forms, tricky overhangs, and parametric designs that challenged our printers and our imaginations. We had the pleasure of learning with Shelby Doyle, AIA, an Associate Professor of Architecture at Iowa State University and co-founder of the ISU Computation & Construction Lab. Her expertise in digital fabrication and design-build education brought valuable insights to our explorations, pushing the boundaries of what we could achieve with recycled materials and large-format 3D printing.

3D printed coffee mug caddy with cups

But one of our favorite prints? A five-mug coffee caddy we designed because we were too lazy to take our mugs back to the kitchen one by one. Turns out the kitchen staff liked it too as it’s a recurring problem!

table with 3D printed designs

Functional Tools, Fun Fixes

A lot of our most downloaded open-source designs are little things that solve specific, everyday problems stuff that just makes life smoother:

Macbook Cable Reel Case

macbook pro charger with 3D printed cable organizer case
MacBook 140w Flexi Cable Wrap Case, for untangled, compact, backpack storage

Flexi Pocket Phone Stand

orange flexible 3D printed phone stand
Inspired by the question: "What if we made a one-piece phone stand durable enough to live in your wallet?"

Oval Lock Cable Ties

3D printed orange cable tie holding cables

Inspired by SSgt Hart during our Gigalab demo at Cannon Air Force Base, she needed a better way to manage cables, had a great idea, sketch it out for us and we helped turn that need into a print anyone can use!

Wormhole Whistle

Gray 3D printed whistle with a hole and string in the middle

These weren’t built for retail. They were built for daily use, most came to life in under an hour, sparked by someone asking, “Hey, can you print something for this?” or even just a playful thought like, “What if we 3D print a whistle?”

A Year of Creative Response

Over the past year, we’ve shared over 50 open-source designs. Some are silly. Some are super niche. Some are actually really useful. Most are a little of all three.

What they all have in common is this: they came from the community, and they’re going back to the community. Free. Open. Ready to print.

Whether it’s a bookmark, a birdhouse, or a prosthetic leg cover, every design came from a simple idea: listen, learn, make, and share.

We believe 3D printing isn’t just a trend. It’s a tool for local problem solving, education, expression, and play. That’s why we do #FreePrintFriday .

So what’s next?

Gif image of GigabotX 3D printing a chair

We’ve still got a backlog of unreleased prints. Expect more cultural remixes, more functional tools, more weird stuff. Maybe even more community collabs!

Got an idea? Shere it with us by filling out our #FreePrintFriday form, we’d love to hear it!

Here’s to another year of printing what matters (and what’s fun). See you Friday and happy printing!

– Michael C. Pujols Vázquez and re:3D team

Michael C. Pujols Vázquez

Blog Post Author

re:3D Goes to Hawai’i

re:3D is a proud and active member of America Makes, an organization which works to accelerate the adoption of additive manufacturing (AM) and supports global U.S. manufacturing competitiveness as one of nine Manufacturing Innovation Institutes (MIIs) operated by the Department of Defense (DOD). re:3D was invited by America Makes to join them in their expo booth at the 2025 Pacific Operational Science and Technology (POST) conference, recently held in Honolulu, Hawai’i. POST, hosted by the National Defense Industry Association, provides a venue for collaboration between the DOD, academia and industry to address challenges within the Indo-Pacific theater.

America Makes Booth at the POST 2025 Expo
America Makes booth at the POST 2025 Expo, shared with re:3D and Craitor
America Makes booth at the POST 2025 Expo, shared with re:3D and Craitor

During the expo, re:3D displayed and demonstrated a system under development for NASA to convert logistics waste into articles of need in space, along with discussing the company’s several Gigalab projects. (You can read a bit more about those projects in a previous blog post here.) There was a positive response to these projects with good feedback and some new contacts and references to follow up with for future collaborations. The America Makes team, including their representatives at POST, Ed Herderick and Kimberly Gibson, were fantastic partners and hosts.

Patrick discussing the benefits of recycling stowage foam in space at POST 2025
Patrick discussing the benefits of recycling stowage foam in space at POST 2025

Also sharing the booth was another America Makes member company, Craitor. The team at Craitor has worked closely with units across service branches to develop an expeditionary 3D printer capable of operating in extreme environmental conditions. Their FieldFab printer can keep printing while being violently jostled in the back of a moving truck, caught in a -40°C blizzard or drenched in a tropical monsoon. Their booth display has the FieldFab mounted on a wobble-table so you can kick the printer while it’s running – something we’ve probably all wanted to do at one time or another. It was great meeting Eric Shnell, Dan Valdes and Will Landry at the event. The re:3D team wishes them all continued success.

After many years, Mike finally got to kick a 3D printer and not feel bad about it

Midweek, after the expo was over, Kimberly Gibson arranged for re:3D to visit Min Plastics & Supply, a family-owned sheet plastics distributor and custom manufacturing company. Andrew and Aaron Min were gracious hosts and discussed possibilities for recycling drops and swarth from their manufacturing processes and using additive for creating custom sign mounts, skylights and tooling. Manufacturing and distributing in the middle of the Pacific Ocean has a whole range of challenges and opportunities to explore, and we look forward to further discussions with the Min Plastics family.

Aaron Min, Michael Pujols, Kimberly Gibson, Patrick Ferrell and Andrew Min at the Min Plastics factory in Honolulu, Hawai’i. (Image Credit: Kimberly Gibson and America Makes)
Aaron Min, Michael Pujols, Kimberly Gibson, Patrick Ferrell and Andrew Min at the Min Plastics factory in Honolulu, Hawai’i. (Image Credit: Kimberly Gibson and America Makes)

re:3D was also honored to be selected as a demonstrator for the POST Field Experimentation (POST FX), held at the end of the conference at the Marine Corps Base Hawai’i, Kane’ohe Bay. The purpose of POST FX is for demonstrators (mostly government organizations, military units and private companies) to demonstrate technologies or capabilities which support the Indo-Pacific area of responsibility, including priorities for advanced manufacturing and contested logistics which are addressed by re:3D’s Gigalabs and other point-of-need tools using recycled materials. We shipped a granulator and a GigabotX printer to Hawai’i for the POST FX event and demonstrated printing mini drone bodies from reclaimed drones. “Drones from Drones” was an attractive concept to the attendees who stopped by to observe and learn more, including Mr. Michael Holthe – Performing the Duties of Assistant Secretary of Defense for Science and Technology, Office of the Under Secretary of Defense for Research and Engineering.

Patrick describing the process of printing “Drones from Drones” at POST FX 2025
Patrick describing the process of printing “Drones from Drones” at POST FX 2025

While in Hawai’i, we were obligated to do a little sight-seeing, and of course we went to a luau. Mike is never one to stop working, so he took the opportunity during the show to scan a large tiki near the stage at the Aloha Tower in Honolulu. He cleaned it up and posted it for all to share and print as his weekly “Free Print Friday” on Thingiverse. You can find the model file here. Mike also scanned the anchor from the USS Arizona on display at the Pearl Harbor National Memorial and has it published here.

re3D Goes to Hawai’i - Polynessian tiki statue at the Aloha Tower plaza in Honolulu_1
re3D Goes to Hawai’i - Polynessian tiki statue at the Aloha Tower plaza in Honolulu
Polynessian tiki statue at the Aloha Tower plaza in Honolulu, Hawai’i.

The island of O’ahu presented jaw-dropping views everywhere, and the people there really do have a special ‘aloha spirit’, all of which made the looong plane ride worth it. It’s no wonder that Hawai’i is such a popular vacation destination.

re3D Goes to Hawai’i - Beaches
re3D Goes to Hawai’i - waves
Beaches. Lots of beaches.
Byodo-In Temple, Ahuimanu, Hawai’i
Byodo-In Temple, Ahuimanu, Hawai’i
re3D Goes to Hawai’i - Sunset at Waikiki Beach
re3D Goes to Hawai’i- Sunset at Waikiki Beach
Sunset at Waikiki Beach, Honolulu,Hawai’i.

Until next time, Happy Travels and Happy Printing.

Patrick Ferrell & Mike Pujols

Blog Post Author

Engineering Updates – 3D Printing, Part Cooling, Firmware and More!

re:3D was on the move last year – literally. But the crew has settled into the new Austin facility with a continued passion for tackling the challenges of additive manufacturing. New faces have joined the Engineering and R&D Teams, and they have all been making impressive progress during the sometimes messy results of a relocation. This is a long-overdue look at some of their recent work.

The Gigabot FFF (Filament) 3D Printing Platform

Early last year there was a company-wide exploration of how and why ‘filament grinding’ was affecting our customers. Follow-up work has focused on cooling methods – both for the extruder mechanism and for part cooling. Improvements in cooling the extruder heat break reduces filament softening (i.e., “heat creep”) in low-temperature materials such as PLA which is a contributing factor to grinding and ultimately print failure. Other thermo-mechanical properties of the extruder are being evaluated as well, with the goal of better thermal management of the filament for more reliable extrusion. Upgrades to part cooling are also being tested. For many thermoplastics, the goal is to extrude above a certain temperature and let the polymer bond to the previously deposited layer (if there is one), and then solidify to maintain the desired geometry as the nozzle travels onward. The rate at which the plastic hardens affects how fast the nozzle can travel without compromising the quality of the print. Often, by appropriately cooling the extruded plastic with forced air, the plastic still bonds, but the geometry is rapidly set and the nozzle can travel faster – ultimately completing the print more quickly. Rapid setting of the polymer also allows for improved performance when printing bridges or overhangs.

With a new approach to thermal management, small, square axial fans are still used to cool the extruder heat sinks, but radial blower fans are used to provide higher-velocity air at the nozzle tip for part cooling (Figure 1, left and center). With this approach, unsupported overhangs of up to 70° are achieved before scoring “poor” using standard overhang print tests. Print speed can also be dramatically increased. The cooling upgrade allowed a standard 3DBenchy model [1] to be printed in 32 minutes with good quality (Figure 1, right) – down from 70 minutes.

New Gigabot extruder cooling design render
Gigabot extruder
Black 3D printed Benchy
Figure 1: New Gigabot extruder cooling design under test (a-B); 32-minute 3DBenchy printed using upgraded cooling (c).

The Engineering Team is also responding to the re:3D user community’s request for a conversion kit to use 1.75mm filament on their Gigabot printers. The new dual-extruder design has been extensively tested on multiple materials internally and will be sent to external beta testers soon.

The GigabotX FGF (Pellet) 3D Printing Platform

Product development on the GigabotX (GBX) in recent months has been focused on a mount for a bed sensor to incorporate bed mesh compensation software correction, along with an implementation of part cooling for the GBX extruder. Bed mesh compensation will be performed with the same eddy current sensor now under beta test on the Gigabot filament machines, but the design challenge is to create a mechanically stiff mount at the end of the long extruder system. As part of this mount, cooling fans and ducting are being incorporated to provide forced-air part cooling. The reasons for part cooling are described above, but with the larger bead sizes on the GBX, the thermal mass of the extrusion is generally larger, and the need for part cooling is even more critical – especially for bridging and overhangs. It can also promote easier breakaway of support material from the print.

With the part cooling design now under test (Figure 2), PLA is bridging over 40mm with minimal drooping (Figure 3, left) and able to create acceptable bridges and spans over 100mm (Figure 3, right). Overhangs are also improved, and support structures more easily break away by hand, leaving clean parting surfaces.

Experimental mount for bed sensor on GBX extruder
GBX part cooling fans
Figure 2: Experimental mount for a bed sensor on the GBX extruder shown in green (a); GBX part cooling fans attached to the back of the extruder cover (b).
3D printing 60mm unsupported bridging part cooling on GBX
3D printing poor bridging example
3D printing good bridging example
Figure 3: 60mm bridging with part cooling on a GBX (a); poor bridging and spanning without part cooling (b); good bridging and spanning over 100mm with part cooling (c).

At the other end of the extruder, improvements are underway to improve the reliability and consistency of material throughput. The extruder motor is connected to the extrusion screw through a jaw coupler, which uses a polymer spider interface between two hubs. If overheated or over-torqued, this spider can become deformed, potentially affecting extruder performance. This style of couple also allows for undesirable axial motion of the extruder screw. A new disc coupler is being tested with good results (Figure 4).

GBX disk coupling
Figure 4: New GBX disc coupling under evaluation.

Throughput problems can also be caused when the feedstock (pellets or flake) bridges within the input to the extruder. This material bridging (buildup, jamming, etc) introduces inconsistencies to the flow of material into the extruder which results in underextrusion.

This is more pronounced when using feedstock with irregular morphology and low apparent density (e.g. granulated water bottles), which do not pack tightly or flow well into the extruder under gravity alone.

To address this, over 40 versions of a “crammer” that actively feeds material into the extruder have been tested over the years, with the current version called the “beta” crammer (Figure 5). This crammer successfully reduced inconsistencies in the extrusion rate, successfully printing rPET flake at the same rate as rPET pellet. While the crammer showed great potential for printing with irregular flake, unfortunately material bridging still happened upstream from the crammer (at the hopper-hose and hose-barb connections). To take full advantage of the crammer’s abilities, it is important to design a system to reliably resolve material bridging in the feed tube.

Figure 5: Current ‘beta’ crammer design.

The most important recent design change to the crammer has been to the feedstock hose clamping mechanism. The tubing was originally connected using a metal hose barb and a worm gear hose clamp, similar to garden hoses. Because the hose barb fits inside the hose, the diameter of the feed path decreases at the interface, creating a stepped region that is very prone to material buildup. To address this issue, the hose barb has been replaced with two printed parts that secure the hose from the outside using screws (Figure 6). The new hose clamp design has been tested for well over 100 hours, and showed zero cases of material bridging with all pellets and most flake feedstocks. The flakes that still showed some trouble, including granulated plastic ID cards and shredded water bottles, had particularly irregular morphology due to its original thin thickness.

hose clamp design render
Figure 6. CAD image of new hose clamp design.

For feedstocks with more extreme morphologies, multiple solutions have been considered, including fluidized beds and vibration motors.

The fluidized bed system designed by Dr. Christopher Pannier’s team at the University of Michigan-Dearborn [1] sends compressed air upstream from the feed throat (Figures 7 and 8). With the right combination of air pressure and flow rate, it is possible to create an environment where solid particles behave like a fluid – a “fluidized bed”. Under this condition, flakes can flow freely through the path without building up on top of each other. Dr. Pannier’s team has tested this system to identify appropriate combinations of air pressure, air flow rate, and duty cycle that produce ideal fluidized bed conditions. However, as of today, only one material of controlled sizes (granulated rPLA, sifted 2~3mm) has been tested. To replicate similar results and identify combinations of parameters for other materials and feedstock morphologies, extensive testing is required.

Figure 7: Fluidized bed system implemented on a GBX. (Image credit: Pannier, 2023)
Figure 8. Fluidized bed system configuration. (Image credit: Pannier, 2023)

Another option to reduce bridging is simply attaching one or more motors to the feed tube, generating vibrations or impact to remove buildups. There have been previous investigations into this solution at re:3D between 2021 and 2022, but the team faced issues including vibration-induced fatigue failures in wires and the printed feed throat. Eventually, this idea was abandoned as the team started to focus on the development of the crammer, which increased the throughput of the machine considerably. The vibration motor system helped with the consistency in extrusion rate by breaking up material buildup, but had little to no effect on the extrusion throughput. The vibration motor system could potentially be a great partner for the current crammer system, as they complement each other and address separate issues. The vibration motor system is not only a simple and cheap implementation, but also does not require major modifications to existing parts.

In a recent re-investigation of the vibration motor system, the motor was mounted directly onto the hose – independent from the extruder body or the crammer – such that the vibrations do not affect other systems negatively. Because constant operation of the motor may cause overheating and also accelerate vibration-induced fatigue, the motor was operated with a duty cycle using custom G-code or external python scripts. Quick testing showed promise, as even short bursts successfully broke up any material buildup along the hose. While no quantitative tests were conducted, the effect of vibrations were easily visible through the transparent feed tubing and also on the printed parts that lacked telltale signs of bridging-induced underextrusion (Figure 9). For the vibration motor system to be implemented, it will require a more robust mount design that reduces the noise (currently 50-60 dB) and secures the motor while sustaining vibrations over an extended period of printing time.

vibration motor on a GBX
recycled polycarbonate 3D printed moai
Figure 9: Vibration motor attached to GBX feedtube (a); recycled polycarbonate prints without and with vibration motor activated (b).

For now, a few minor tweaks to the ‘beta’ crammer have resulted in reliable and consistent extrusion performance for most feedstock materials and morphologies. But it’s good to have experience with additional options should the need for additional bridging mitigation arise.

Software Improvements

The software team at re:3D is incredible. Their most recent work to improve customer experience with the Gigabot and GigabotX printers includes bed mesh compensation, the new Klipper stack V0.5.0, improved print recovery, and a new web application: Helm.

Mesh Compensation Enhancements

Reliable printing requires reliable, high-quality first-layers. One key factor to a successful first layer is proper bed leveling, or more properly, bed tramming. Manually leveling the large print beds on the Gigabot and GigabotX printers might take a bit of practice, but the system does remain stable – until heat is applied. When materials (especially metals) heat up, they tend to expand. Depending on the mechanical constraints on the object, its shape will change. In the case of a flat metal plate with fixed constraints as shown in Figure 10, heating a print bed can cause bowling or warping at these elevated temperatures. No matter how much you try to “level” the bed, the print nozzle will not remain a constant distance from the bed surface without active correction.

Figure 10: Depiction of thermally-induced deflection of a mechanically constrained bedplate.

Enter “mesh compensation”. In this method, a map, or mesh, of the now-warped bed is measured with a sensor. This heightmap (Figure 11) can then be used in a mathematical algorithm to correct for changes in distance between the nozzle tip and the bed surface, and the firmware will automatically adjust the z-axis height to maintain the appropriate “height”, leading to improved first-layer adhesion, consistency and overall quality.

Figure 11: Bed heightmap generated from the eddy current sensor and bed mesh compensation software.

The team has been working hard to perfect mesh compensation to ensure it’s ready for release. An eddy current scanner was selected for its high precision, performance, and rapid data collection. Despite the clear benefits, the scanner’s reliability was a concern for users. Disconnections during a print would trigger an error and cause the print to fail, as the scanner is recognized as a main control unit (MCU), and Klipper naturally shuts down when an MCU is unresponsive or disconnected. During initial beta testing, about 33% of machines experienced these disconnections, which was consistent with in-house testing.

The software team conducted thorough investigations with the manufacturer and explored how Klipper handles MCUs – ultimately deciding to implement a feature in Klipper to declare and allow non-critical MCUs. This change prevents print stoppage if a disconnection occurs, as the scanner is not essential during an ongoing print. After this adjustment there were significant improvements in testing. This enhancement ensures that mesh compensation is not only accurate but also reliable, laying the groundwork for its upcoming release.

Klipper Stack V0.5.0

The release of Klipper stack V0.5.0 was delayed in 2024 due to the move but is now available to download from re:3D’s Github repository. This update introduces fine-tuning for machine parameters, new features, and fixes for existing issues. Currently, the process involves building the operating system, configuring dependencies, and settings, and then creating a copy of the entire OS, which is compressed into an image file for SD card deployment. This method is slow and cumbersome, requiring a near-perfect system state before imaging.

While the Klipper configurations are stored in a GitHub repository, allowing remote updates for machine configurations, system component updates are not possible remotely. V0.5.0 extends the ability to modify certain components, but system-wide modifications remain out of reach. The best approach may be a shift to variant creation of the distribution that grants total control over the OS and its dependencies. This would enable nightly builds and allow every system component to be modified remotely.

Improved Print Recovery

There has also been a lot of work improving the print recovery workflow. The current recovery tool, while useful, requires manual efforts and often results in noticeable layer artifacts. The new method, which is native to the Klipper stack, is fully autonomous and more accurate. It monitors a print in progress, constantly recording the current position of the G-code file by byte. If a stoppage occurs due to an error or other causes, the file is automatically copied and parsed to the exact last G-code line, while preserving the start G-code. This ensures that the print resumes exactly where it left off without creating a layer artifact. This new print recovery feature will significantly reduce the need for manual intervention, making the printing process smoother and more reliable.

The only caveat is that this method doesn’t cover power interruptions. To recover from a power outage, an uninterruptible power supply (UPS) would be required to send a signal to the printer’s Raspberry Pi, triggering a script when a power failure is detected.

Introducing Helm: A New Web Application for Printer Fleet Management

Managing multiple printers in the factory was becoming a challenge, so re:3D’s lead software engineer developed a simple script to query devices on the network and find connected printers. This script has now evolved into a full-fledged web application for printer fleet management, aptly named Helm. Helm offers many features to enhance monitoring and synchronous communication across the network.

Helm is similar to Mainsail in that it uses the Moonraker API to communicate with Klipper, but it automatically detects Klipper printers on the network and displays detailed, dynamic information on a single page (Figure 12).

Figure 12: Helm dashboard.

Here are some of Helm’s key features:

  • Server hosted on the local network for multiple clients
  • Automatic network scanning to connect to printers
  • Status monitoring
  • Display of hostname, IP address, and firmware version
  • Dynamic monitoring of status, state messages, temperatures, and command responses
  • Multi-printer selection for command execution
  • File upload/deletion
  • Start/stop prints
  • List G-code files on a particular machine
  • List commands
  • Send G-code commands
  • Set temperatures
  • Cooldown heaters
  • Firmware restart
  • Emergency stop

Helm is still a work in progress, but it’s an open-source project and open to contributions. You can try the application yourself, report problems, contribute, or follow progress here: Helm on GitHub. Helm is designed to simplify printer management and will continue to evolve with input from the community, ensuring it meets the needs of users managing multiple printers.

R&D Programs

re:3D is proud to have a robust R&D program, sponsored in part through industry and government awards and contracts. Each of these could consume its own blog post (and perhaps someday will, disclosure rules permitting). For now, here’s a brief summary of recent and ongoing programs re:3D is engaged with through the Department of Defense, NASA, the Department of Energy and the National Science Foundation.

re:3D Gigalabs (PRSRT, DOD, NSF)

One of the visions of re:3D’s founders was to provide a means of production to people in need, who could fabricate parts from local and salvaged materials. The Gigalab is a huge step towards fulfilling that vision. Within a modified 20-ft shipping container, the Gigalab Mobile Recycling Facility can contain all of the equipment required to break down waste plastics to use as feedstock for printing functional items with a GigabotX printer. Multiple variants of Gigalabs have now been fielded at four locations: the Engine-4 coworking lab in Bayamón, Puerto Rico; an Army Corp of Engineers facility at Fort Leonard Wood, Missouri; Cannon Air Force Base in New Mexico; the Austin Habitat for Humanity ReStore location in Austin, Texas (Figure 13).

re:3D Gigalab at Engine 4 Puerto Rico
interior of re:3D Gigalab at Engine 4 Puerto Rico
re:3D Gigalab at Fort Leonard Wood
re:3D Gigalab with wind turbine at Cannon Air Force Base
Figure 13: Gigalab at Engine-4 in Bayamón, PR (a-b); Fort Leonard Wood Gigalabs (c); Gigalabs with wind turbine power at Cannon Air Force Base (d).

You can learn more about re:3D’s Gigalab at Engine-4 in Puerto Rico in an earlier re:3D blog post here: October 2023. Last year’s highlights from the US Army and US Air Force Gigalab projects included logistics challenges, travel to Los Angeles to install a custom energy-management system and fabricating (and flying) small drones printed from recycled drones (Figure 14).

Crane installing wind turbine on re:3D Gigalab
re3D installation of a custom energy management system for the US Army Gigalabs
3D printed drone part
Drone with 3D printed parts
Figure 14: Installation of a wind turbine on a USAF Gigalab at re:3D’s Carmine, Texas interim test site (a); installation of a custom energy management system for the US Army Gigalabs at Wenzlau Engineering in California (b); iterations of printed “drones from drones” at Cannon Air Force Base in New Mexico (c-d).

ReCreateIt (NSF)

ReCreateIt is a multinational collaboration led by re:3D to transform waste plastic into valuable products with 3D printing and community-led design. The Gigalab located at the Austin Habitat for Humanity ReStore is a part of this program, which is funded through the National Science Foundation’s Convergence Accelerator. In order to maximize the value of “trash-to-treasure” in converting waste thermoplastics collected at the ReStore into printed goods of value, re:3D now employs a polymer scientist dedicated to this project who will investigate and optimize the processing and printing parameters to best recycle plastics via material extrusion additive manufacturing (3D printing).

Recent success in 3D printing with recycled polypropylene (PP) is evidence of the benefit of having a polymer scientist on staff. PP is the second most widely produced plastic in the world, and is commonly used for consumer items, including storage bins, which are available in large numbers for recycling at the ReStore (Figure 15(left)). However, PP is commercially recycled at a rate of less than 5% – partly due to industrial processing and economic challenges. Additionally, as with all members of the polyolefin family of polymers, it is notoriously difficult to use as a feedstock in 3D printing, even in a neat or virgin state, let alone as recycled granulate. But the perseverance and dedication of the ReCreateIt team is paying off as evidenced by the printed vase in Figure 15(right), along with many other great successes.

ReCreatIt team sorting plastics for 3D printing
3D printing vase from recycled material
Figure 15: Members of re:3D’s ReCreateIt team sorting plastics at the Austin Habitat for Humanity ReStore (a); decorative vase printed from polypropylene laundry baskets and storage totes (b).

Low-SWaP Waste-to-Print System (NASA)

Remember the Gigalab – a converted 20-ft shipping container with the equipment to granulate plastics and print objects of use? Now imagine a similar system the size of a dorm refrigerator that uses half the power of a common space heater and is designed to work in space. This is the objective of a research contract re:3D was awarded through NASA for the Artemis Gateway program. The GigabotX has been repackaged into a low size, weight, and power (SWaP) version and integrated with a custom granulator (Figure 16(left). The system is intended to recycle packing foams which are necessary to protect payloads during liftoff, but are largely unnecessary once in space – or on the lunar or Martian surface. These foams can then be recycled for repair parts, construction materials or other items which would otherwise need to be delivered separately (at significant cost). The system isn’t ready for flight testing yet, but interim hardware demonstrations have already been performed for NASA on-site at Kennedy Space Center in Florida.

re:3D Low SWaP 3D printer and granulator system
tetrahedral dowel connector 3D printed from shipping foam
Figure 16: Low-SWaP printer and granulator system (a); tetrahedral dowel connectors printed from shipping foam (b).

“Bigger, Better, Faster” FGF (US Army)

Building on the success of one of re:3D’s R&D contract with the US Army to demonstrate printing from waste in a Gigalab, sequential funding was secured to print bigger, better and faster – using a wider range of recycled materials as feedstock. This will still be a cartesian FGF printer built on an extrusion frame, but larger in footprint than re:3D’s TerabotX (Figure 17). The extrusions are larger and stiffer, and the design is more easily scalable in the length axis to accommodate future development goals. The bed will be stationary with better access from the front and back to aid print monitoring and removal. For motion control, stepper motors are being replaced with servo motors for improved speed and torque performance, and linear screws are replacing belt drives for translation. The standard ArchiMajor control board will still be used, but a custom breakout board has been designed in-house to provide servo motor control, and the Klipper GUI interface is getting an upgrade to better reflect the operation of an FGF printer.

Figure 17: FGF R&D printer lower frame for the US Army. Hardware Engineer for scale.

re:3D is very pleased to collaborate with Dr. David Kazmer and his team at the University of Massachusetts Lowell to design, fabricate and optimize a new extruder with a novel screw for this project. The extruder length won’t change much from the existing GBX design, but the screw’s diameter will double and provide a very significant increase in throughput. Additional support is coming from the University of Maine’s Advanced Structures and Composites Center (ASCC). They will be leading the effort to develop recycled biocompounds – that is, feedstock materials produced from recycled polymers and wood or paper waste. This is an exciting R&D project with many possibilities for cross-development into re:3D’s portfolio of standard printers and other collaborative opportunities.

Additively Manufactured Thermal Protection Systems (NASA)

When a spacecraft enters a planet’s atmosphere, friction generates extreme heat which can damage the craft and payload (human crew or otherwise). Thermal Protection Systems (TPS) are materials designed to insulate and dissipate that heat energy – often through charring and re-radiation. Under an R&D contract with NASA / Johnson Space Center, re:3D is developing a pilot manufacturing system to print TPS materials directly onto spacecraft heatshields and other structures. Dr. Brett Compton and Dr. Damiano Bacerella (University of Tennessee – Knoxville) are developing and testing a phenolic-based foam, which when cured at elevated temperatures forms a ceramic-like TPS structure (Figure 18(a)). re:3D, in turn, is designing and building a printer to deposit the foam onto a large, non-planar aluminum dish. This requires a 5-axis printer with advanced controls (Figure 18(b-c)). re:3D is collaborating with Siemens/CATCH on the industrial motion control system, and with Addiguru for deposition monitoring.

Besides the unique opportunity to work on #supercoolNASAstuff, this project is giving re:3D additional experience with new industrial control systems, 5-axis tool-path planning and printing thermoset materials. Thermosets differ from thermoplastics in that they start out in some fluid form and require heat to harden (rather than just melting and recooling, as do thermoplastics). This gained experience with thermosets will allow re:3D to provide new opportunities to work with customers on a wider range of material extrusion projects. The deposition monitoring system being spearheaded by Addiguru may also be modified for future inclusion in re:3D’s commercial products. Finally, this provided the R&D team a reason to purchase a large truck oven (Figure 18(d)) for curing the TPS foam after it is deposited onto the aluminum dish. It might also be for a dual-use on Pizza Fridays.

re:3D High Energy testing of TPS foam
re:3D AMTPS 3D printer frame
re:3D ViscoTec deposition head on multi axis mount
re:3D Blue M truck oven
Figure 18: High-energy testing of TPS foam (a); AMTPS printer frame (b); ViscoTec deposition head on multi-axis mount (c); Blue-M truck oven (d).

Water Bottle Granulation (DOE)

Through a Cooperative Research and Development Agreement (CRADA) with Oak Ridge National Laboratory in Tennessee, re:3D is partnering with Oak Ridge’s Manufacturing Demonstration Facility (MDF) to develop a low-cost and accessible granulator that can break down water bottles into appropriate flake (Figure 19(left)), even if they are still full of water. Collaborators at ORNL/MDF are also investigating the best ways to separate the different polymer components of the granulated water bottles (Figure 19(center, right)) so they don’t have to be pre-processed to remove the lids, safety rings and labels – often done manually in small-scale operations. Phase II of the project was approved in 2024.

re:3D plastic granulator for 3D printing
granulated water bottle into PET flake for 3D printing
granulated PP and PE water bottle lid and label into flake for 3D printing
Figure 19: Plastics granulator with modified controls to safely process wet water bottles (a); separated water bottle flake: PET bottle portion (b) and PP/PE lid and label portion (c).

This was a long post. But there was a lot to cover from last year, and it’s been awhile since an engineering update was posted to the blog. Thanks for sticking with it, and stay tuned for more (frequent) updates.

As always… Happy Printing!

References

[1] 3DBenchy.com
[2] Al Nabhani, D.; Kassab, A.; Habbal, O.; Mohanty, P.; Ayoub, G.; Pannier, C. Benchmarking the Tensile Properties of Polylactic Acid (PLA) Recycled Through Fused Granule Fabrication Additive Manufacturing. In Proceedings of the Solid Freeform Fabrication Symposium, Austin, TX, USA, 14–16 August 2023. https://doi.org/10.26153/tsw/50919

Patrick Ferrell

Senior Engineer

GIGAPRIZE 2024 IS LIVE!

We Have a BIG Announcement!

Congratulations to our 2024 Gigaprize winner – OrthoAdditive Africa in Cape Town, South Africa! OrthoAdditive Africa’s mission is to overcome barriers to healthcare access for people living with disabilities through CAD and additive manufacturing technology. They propose to use the Gigabot 4 FFF 3D printer we will be sending them to prototype a range of seating, positioning, and mobility devices currently in development with their collaborators Shonaquip.

You can learn more about their plans for Gigabot in their video:

A huge shoutout goes out to all of the outstanding applicants for this year’s prize who are doing amazing things in their communities here in the US and abroad – Asmbly Makerspace, Black Sheep Food Initiative, the Citizens Archive of Pakistan, EveryShelter, SOC Films, and the Welman Project! Entry videos for all of this year’s amazing applicants can be viewed on a dedicated playlist on our YouTube channel here.

Thank you to our amazing panel of judges for taking time out of their busy schedules to evaluate the application videos and determine the winner of this year’s Gigaprize. Please make sure to sign up for our newsletter on our website to find out when the next Gigaprize is taking place! 

THE FINALISTS

re3D Gigaprize 2024 - Assmbly Makerspace logo
re3D Gigaprize 2024 - Every Shelter
re3D Gigaprize 2024 - Orthoadditive Africa

WHAT IS THE GIGAPRIZE?

The Gigaprize is a competition re:3D runs to support other amazing individuals and groups committed to building community, one layer at a time. For every hundred printers we sell, we donate one Gigabot large-format, industrial filament 3D printer to an individual or organization that will use it for a good cause.

Gigabot 4 3D Printer

WHO ARE OUR JUDGES?

An external team of impartial judges with a wide variety of experience and expertise will evaluate applications for the Gigaprize during the second half of December. Our stellar lineup this year includes:

Maria Arteaga

Maria Arteaga

Talent and Workforce Development Coordinator

Opportunity Austin
Berga, Gustavo

Gus Berga

Artist
Ellis, Luke

Luke Ellis

Account Executive

Indeed
Gallagher, Courtney

Courtney Gallagher

CEO

EarthViews
Laszlo, Joe

Joe Laszlo

Head of Industry Insight & Engagement

Shoptalk
Mayes, Jamie

Jamie Mayes

LIFT Consultant

UT Austin Honors Program
Morgan, Madelyn

Madelyn Morgan

Circular Economy Program Manager

City of Austin, TX
Ryan Murray

Ryan Murray

Management Consultant

McKinsey & Company
Riley, David

David Riley

Lead Instructor, Digital Modeling & Fabrication

IYRS
Zane Ross

Zane Ross

Engagement Manager

America Makes/NCDMM
Szmara, Pamela

Pamela Szmara

Founder and CEO

Pamton 3D

THE GIGAPRIZE 2023 WINNER

Our 2023 Gigaprize winner was Brookwood in Georgetown! Their vision of empowering adults with special needs with the Gigabot 4 3D printer to create art and change lives earned them this recognition.

3D printer with the Gigaprize instructions on how to apply

Michael pregill

Blog Post Author

The Force is Strong with This Maker: Mike Ogrinz & His Life-Size 3D Printed Grogu

Mike Ogrinz is a maker through and through, deeply embedded in the re:3D community since backing the original Gigabot on Kickstarter in 2013. He originally purchased the Gigabot to 3D print the parts for his life-size replica of Robby the Robot. Over the years, Mike upgraded his Gigabot 2 to have a heated bed and dual-extruder capabilities. This has given Mike the ability to use the Gigabot for numerous projects, including making re:3D a life-size 3D printed Grogu (Baby Yoda) in exchange for our Series II All-Metal Body Extruder. You can read Mike’s blog post about how Grogu was created below, originally posted on his website, ogrinz.com.

I’ve had my Gigabot 3D printer for almost a decade now (wow) and every now and then the company behind it (re3D) have asked “Would you print something out for our in-house museum?” They’ve even offered to pay for the filament, shipping, etc. At one point, I *almost* sent them one of the spare heads from my Robby the Robot project, but the thought of all that sanding, priming, and painting scared me off.

Then a few months ago Jennifer from re3D reached out again. She asked if I’d be interested in making something, and even offered me some credit in their store. Well, I did have my eye on a set up fully-machined dual aluminum extruders as an upgrade for my Gigabot…. So I asked, “What would I have to make you in exchange for those parts?”

Jennifer almost immediately answered “Baby Yoda!” and the deal was struck. I figured with the filament cost probably coming in around $100, I was getting the better end of the deal. But of course, there was a lot of finish work required. And since Grogu has so many organic surfaces and details, it had to all be done by hand. I had to completely finish the replica too, which meant learning how to use an airbrush (well, it meant buying and airbrush and then learning how to use it). But I am extremely happy with how it came out. Now if I only could find the time to install those metal extruder mechanisms…

Grogu's 3D printed body on top of a Gigabot 3D printer platform
3D printed Grogu's head
3D printed Grogu with prime paint
3D printed grogu with painted shadow details
3D printed grogu with a BB8 model
3D printed Grogu on a sit playing an arcade Star Wars game
Full color 3D printed Grogu on a table

The 3D printed Grogu took 134 hours to print and used three rolls of PLA Silk filament.

The original Grogu file came from MarVin_Miniatures on Thingiverse. You can also follow them on Facebook, @MarVinMinis.

To learn more about Mike’s other projects click here. You can also check out Mike’s YouTube Channel, Ogrinz Labs, where he posts educational and informational videos on his awesome builds.

3D printed Grogu using the force to move a 3D model in the computer
Grogu with re3D's wall sculpture
Grogu with re3D's pellet and flake material storage
Grogu in front of a computer with a 3D model
Grogu on top of a table, in front of a box with screws

Jennifer Dennington

Blog Post Author

Reimagining Themed Experience Design with Large-Scale 3D Printing: UCF’s Domain Bizarre Project

In the highly competitive realm of themed experience design, standing out requires not only innovative concepts but also the ability to present those concepts in a compelling and tangible way. This was the challenge faced by our project team at the University of Central Florida’s (UCF) Themed Experience Master’s Program. Our project, “Domain Bizarre,” aimed to revolutionize the theme park experience with a queueless land design. Key to our success was the utilization of a large-scale 3D printed massing model, generously provided by re:3D Inc.

The Power of Large-Scale 3D Printing

In themed entertainment design, the devil is in the details. Traditional desktop 3D printers, while useful, often produce models that are too small to effectively convey the full scope and intricacy of a design. This is where re:3D Inc.’s large-scale 3D printing capabilities came into play, allowing us to create a 2ft x 2ft massing model of Domain Bizarre.

Why Printing BIG Matters

The ability to print a large model was crucial for several reasons:

  1. Detailed Realism: Larger models capture finer details and provide a more realistic representation of our design. This level of detail is essential for themed entertainment, where every element contributes to the overall narrative and guest experience.

  2. Comprehensive Visualization: A substantial model offers a more comprehensive view of the project, helping our team and the judges better understand spatial relationships, proportions, and the overall layout of Domain Bizarre.

  3. Impactful Presentations: For our presentation, the large-scale model made a significant impact. It allowed the judges to truly grasp the scale and complexity of our design, enhancing their understanding and engagement.

Domain Bizarre: Concept to Reality

Domain Bizarre is a queueless land designed to be integrated into an existing theme park. Our goal was to create a seamless, immersive environment where guests could explore at their own pace without the constraints of traditional queues. Here’s how the large-scale 3D printed model facilitated this vision:

  1. Design Breakdown: The 2ft x 2ft model allowed us to break down different areas of Domain Bizarre, illustrating how story beats unfolded across the land. We could clearly show where interactive elements, seating areas, and food stalls were ideally located.

  2. Interactive Elements: By printing large, we could place and adjust interactive elements within the model, ensuring they fit seamlessly into the environment and contributed to the overall guest experience.

  3. Optimized Layout: The detailed model helped us optimize the placement of various features, ensuring that every element—from food stalls to seating areas—was strategically placed to enhance the guest experience.

The Role of re:3D Inc.

While UCF’s Themed Experience Master’s Program provided the platform for our project, it was re:3D Inc. that made our vision a reality. Their Gigabot 3D printer allowed us to create a detailed, large-scale massing model that was pivotal to our presentation’s success. The ability to “print HUGE” provided a level of detail and realism that desktop models simply cannot achieve.

Presentation Impact

The impact of our large-scale model on the presentation was profound. Judges were able to see our world in a tangible form, allowing them to fully appreciate the intricacies and thoughtfulness of our design. The model’s size and detail made it easier for them to visualize how Domain Bizarre would function in real life, enhancing the overall effect of our presentation.

Conclusion

The successful presentation of Domain Bizarre demonstrates the critical role that large-scale 3D printing can play in themed experience design. By collaborating with re:3D Inc., our project team was able to create a compelling and detailed massing model that brought our vision to life. This experience underscores the importance of innovative presentation tools in the field of themed entertainment, paving the way for future projects to push the boundaries of creativity and design.

For our team, the journey of Domain Bizarre was not just about presenting a project; it was about pioneering new methods of visual storytelling and spatial design. With the help of re:3D Inc., we showcased how large-scale 3D printing can transform abstract concepts into tangible realities, setting a new standard for themed experience presentations.

Mike Strong

Blog Post Author

TerabotX 2 3D Printers

TerabotX 2

Three Zone Independently
Controlled Barrel Heaters
5/8" Extruder Screw with a
16:1 L/D Ratio and a0.4,
0.8, 1.75 or 3mm nozzle
9 Point Bed Leveling
NEMA 17 & 23
Stepper Motors
0.5" Aluminum Heated
Bed with PRINTinZ
Leveling Caster Wheels
Full Color 10"
LCD Touchscreen
with Mainsail for
Klipper interface
Linear Rails on All Axis
7.8 kg Hopper Capable
of 24h of Printing
Between Refills
32bit ArchiMajor
Control Board

Fulfill your large-format FGF 3D printing needs with TerabotX 2, expanding the size of your build volume to 879 x 908 x 830mm. This direct-drive pellet extrusion based 3D Printer can print from virgin or recycled pellets, flake, or regrind – and bring us even closer to the dream of a circular economy.

A ⅝” extruder screw with a 16:1 L/D ratio powered by a NEMA 23 motor enables 3D printing with 3-5mm plastic granules with melting temperatures below 270ºC. With a larger 0.4, 0.8, 1.75 or 3mm nozzle, TerabotX 2 3D printer reduces the dependence on printing with filament while supporting plastic granule mixing, increasing printing speed and cost savings.

Your open-source industrial 3D printer is powered by a 32bit Ultimachine ArchiMajor control board and Klipper firmware run on a Raspberry Pi. Access TerabotX 2 controls via the Mainsail interface on either the 10” LCD touchscreen or a desktop or mobile web browser.

Hand-crafted in Texas by team re:3D to highly precise standards, your TerabotX 2 3D printer is modular, upgradable and backed by Lifetime Customer Support.

Buy TerabotX 2 Now
Printing

Technology

FGF

Build Volume

879 x 908 x 830 mm

Extruder

Steel 5/8" extruder screw with a 16:1 L/D ratio

Materials

Supports thermoplastics melting below 270 ºC

Granule Size

Supports 3 - 5 mm plastic granules & pellets

Layer Resolution

0.32 - 2.25 mm

Printing Speed

up to 30 mm/sec

Nozzle Diameter

0.4, 0.8, 1.75 or 3 mm

Mechanical

Design

Modular & upgradable construction

Construction

Robust aluminum cartesian frame

Build Plate

Cast aluminum blanchard ground flat 0.5” thick build plate

Stepper Motor

NEMA 17 & 23

Touchscreen

Bot Control

Full color 10" LCD Touchscreen with Mainsail for Klipper interface

Connectivity

Optional network connecting for local monitoring & control

Software

File Transfer Method

USB or Wifi

Open Source

Open source Klipper software stack

Upload File Type

G-code (.gcode) upload file type

Printing Workflow

Includes Simplify3D setting profiles

Electrical

Power

110V 60Hz 20A or
220V 50Hz 10A

Extruder Temperature

Up to 270ºC

Build Surface Temperature

Up to 115ºC

Explore Other FGF 3D Printing Solutions

GigabotX 2 XLT Granular 3D Printer

GigabotX 2 XLT 3D Printer

GigabotX 2 XLT Three Zone Independently Controlled Barrel Heaters 5/8″ Extruder Screw with a16:1 L/D Ratio and a0.4,0.8, 1.75 or
GigabotX 2 Granular 3D Printer

GigabotX 2 3D Printer

GigabotX 2 Three Zone Independently Controlled Barrel Heaters 5/8″ Extruder Screw with a16:1 L/D Ratio and a0.4,0.8, 1.75 or 3mm

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Revolutionizing Chair Manufacturing: A Journey with Rhodes and re:3D’s Gigabot

3 office chairs

Leia em português

Have you ever considered how the chair you are sitting on right now was made? It’s a question that often goes overlooked in our daily lives, yet the answer reveals a world of innovation and creativity shaping the furniture industry. One of the notable players in this space is Brazilian manufacturer, Rhodes. Founded in 1964, Rhodes has been at the forefront of chair component manufacturing, producing around 5 million components annually for various seating solutions, from office chairs to public seating in airports and stadiums.

3 office chairs

Rhodes plays a vital role in providing essential elements for operative chair lines. Key products include bases, columns, and mechanisms, which maintain Rhode’s strong presence as a component supplier. Despite market challenges, especially during Brazil’s economic crisis in 2013-2014, Rhodes has excelled. During the COVID-19 Pandemic, Rhodes expanded into the ready-made chair market, adapting to the growing need for home offices. Currently, Rhodes is a major manufacturer of chairs and chair components in Brazil and exports its products to other Latin American countries, the United States, and some parts of Europe.

Rhodes’ integration of 3D printing played a crucial role in streamlining their manufacturing process and achieving global success. Initially, Rhodes outsourced their 3D printing needs. They would create a computer-aided design (CAD) file for their chair component prototypes, send it to a partner company in Italy, and wait for the 3D printed component to come back. The cost and time constraints prompted Rhodes to explore other alternatives. After a Google search led Rhodes to re:3D, the size and affordability of re:3D’s Gigabot cemented their purchase as Rhodes first in-house 3D printer for prototyping and design iterations. A decade later, Rhodes’ workhorse Gigabot 2 is still going strong, being used to 3D prototype every plastic component of their furniture lines. 

"The Gigabot has paid for itself many times over. Having the capability in-house eliminates development constraints. For instance, I've even created a chair base prototype where each of the five legs was distinct, allowing me to assess the best aesthetic for the product within a single piece."
Júlio Reis - Senior Product Designer at Rhodes
re3D blog - Rhodes chair manufacturing 3D printed part
re3D blog - Rhodes chair manufacturing Prototype 2

Gigabot’s robustness and versatility has allowed Rhodes to seamlessly integrate 3D printing into their development processes. From mitigating design flaws to producing quick 3D prototypes for assessment, Gigabot has been a reliable companion, functioning almost continuously for a decade. But it wasn’t always that easy. It took Júlio a full year of experimenting and learning before getting quality prints from Gigabot, since he had no prior 3D printing experience when Rhodes decided to test the technology. Julio had to determine which material to print with and find a reliable national supplier. He ended up choosing ABS because of its durability, which was key to testing the prototypes before finalizing their design. Júlio built an enclosure for the machine to overcome temperature differences during different seasons and ensure ABS would print year-round. He has also tested every type of glue on the market, including hairspray, to make the prints adhere to the print bed, as re:3D’s original Gigabot 2 did not come with PrintinZ.

"I need to have a prototype to ensure assembly and reliability, especially for the design of the piece. [Gigabot] allowed me to try new fastening technologies, something that wasn't possible some time ago, as I required a mold to create the geometry I needed."
Júlio Reis - Senior Product Designer at Rhodes

Júlio started small, prototyping components of chairs such as caster bases, columns, mechanisms, seats, and backrests. Rhodes also began to use Gigabot to print replacement parts for machines in their factory and has been contracted by their vendors to CAD other non-chair-related products. Because of their success with Gigabot 2, Rhodes purchased a Gigabot 4, which will be an upgrade from their current, single-extruder workhorse. Júlio anticipates enhanced ease of use and agility, allowing for increased prototyping and quicker project timelines. Júlio believes that 3D printing’s strength and effectiveness is well-established and expects the technology to continue influencing the furniture industry.

"[Gigabot] allows you to design things you wouldn't if you didn't have it; it enables you to take more risks, to take more shots. It gives you more bullets to hit the target."
Júlio Reis - Senior Product Designer at Rhodes

The integration of Gigabot at Rhodes exemplifies how innovative technologies can revolutionize traditional industries. Júlio’s insights showcase the profound impact of 3D printing on Rhodes’ development processes, fostering creativity, and enabling the exploration of new design possibilities. Looking towards the future, Rhodes is poised to take its manufacturing capabilities to new heights with the upcoming addition of the Gigabot 4. With its dual-extrusion print head, this advanced 3D printer will enable Rhodes to produce larger, more intricate 3D prototypes, pushing the boundaries of design creation even further. Moreover, by doubling their printing capacity with two Gigabots, Rhodes aims to accelerate their prototyping process, allowing for quicker iteration and refinement of their chair designs. As Rhodes continues to leverage Gigabot’s capabilities, it exemplifies a story of adaptation and innovation in the furniture manufacturing industry that is not slowing down.

Revolucionando a Fabricação de Cadeiras: Uma Jornada com a Rhodes e a Gigabot da re:3D

Você já parou para pensar em como a cadeira em que você está sentado agora foi feita? É uma pergunta que muitas vezes passa despercebida em nossas vidas diárias, mas a resposta revela um mundo de inovação e criatividade que está moldando a indústria de móveis. Um dos nomes mais fortes  nesse espaço é a fabricante brasileira Rhodes. Fundada em 1964, a Rhodes tem estado na vanguarda da fabricação de componentes para cadeiras, produzindo cerca de 5 milhões de componentes anualmente para várias soluções de assentos, desde cadeiras de escritório até assentos públicos em aeroportos e estádios.

3 office chairs

A Rhodes desempenha um papel vital no fornecimento de elementos essenciais para linhas de cadeiras operativas. Os principais produtos incluem bases, colunas e mecanismos, o que mantêm a forte presença da Rhodes como fornecedora de componentes. Apesar dos desafios do mercado, especialmente durante a crise econômica do Brasil em 2013-2014, a Rhodes se destacou. Durante a pandemia de COVID-19, a empresa expandiu seu portfólio para o mercado de cadeiras prontas, adaptando-se à crescente necessidade do home office. Atualmente, a Rhodes é uma das principais fabricantes de cadeiras e componentes para cadeiras no Brasil, além de exportar seus produtos para outros países da América Latina, Estados Unidos e algumas partes da Europa.

A integração da impressão 3D pela Rhodes desempenhou um papel crucial na otimização do seu processo de fabricação e no alcance do sucesso global. Inicialmente, a Rhodes terceirizava suas necessidades de impressão 3D. Eles criavam um arquivo de design assistido por computador (CAD) para os protótipos de componentes das cadeiras, enviavam para uma empresa parceira na Itália e aguardavam o retorno do componente impresso em 3D. Os custos e as restrições de tempo levaram a Rhodes a explorar outras alternativas. Após uma pesquisa no Google levar a Rhodes à re:3D, o tamanho e a acessibilidade do Gigabot da re:3D consolidaram a compra como a primeira impressora 3D interna da Rhodes para prototipagem e iterações de design. Uma década depois, a robusta Gigabot 2 da Rhodes ainda está em plena atividade, sendo usada para prototipar todos os componentes plásticos de suas linhas de móveis. 

"A Gigabot se pagou muitas vezes. Ter essa capacidade internamente elimina as limitações de desenvolvimento. Por exemplo, já criei um protótipo de base de cadeira onde cada uma das cinco patas eram diferentes, permitindo-me avaliar a melhor estética para o produto em uma única peça."
Júlio Reis - Designer de Produto Sênior da Rhodes
re3D blog - Rhodes chair manufacturing 3D printed part
re3D blog - Rhodes chair manufacturing Prototype 2

A robustez e a versatilidade do Gigabot permitiram à Rhodes integrar perfeitamente a impressão 3D em seus processos de desenvolvimento. Desde mitigar falhas de design até produzir protótipos rápidos para avaliação, a Gigabot tem sido uma companheira confiável, funcionando quase que continuamente por uma década. Mas nem sempre foi tão fácil. Júlio levou um ano inteiro de experimentação e aprendizado antes de conseguir impressões de qualidade com a Gigabot, já que ele não tinha experiência prévia com impressão 3D quando a Rhodes decidiu testar a tecnologia. Júlio teve que determinar qual material usar para impressão e encontrar um fornecedor nacional confiável. Ele acabou escolhendo ABS por causa de sua durabilidade, o que foi crucial para testar os protótipos antes de finalizar o design. Júlio construiu uma caixa de proteção para a máquina para superar as diferenças de temperatura durante as diferentes estações, garantindo que o ABS fosse impresso durante todo o ano. Ele também testou todos os tipos de cola no mercado, incluindo spray de cabelo, para fazer as impressões aderirem à mesa de impressão, já que o Gigabot 2 original da re:3D não vinha com a tecnologia PrintinZ.

"Preciso ter um protótipo para garantir a montagem e a confiabilidade, especialmente para o design da peça. [A Gigabot] me permitiu experimentar novas tecnologias de fixação, algo que não era possível há algum tempo, pois eu precisava de um molde para criar a geometria necessária."
Júlio Reis - Designer de Produto Sênior da Rhodes

Júlio começou pequeno, prototipando componentes de cadeiras, como bases de rodízios, colunas, mecanismos, assentos e encostos. A Rhodes também começou a usar o Gigabot para imprimir peças de reposição para máquinas em sua fábrica e foi contratada por seus fornecedores para criar em CAD outros produtos não relacionados a cadeiras. Devido ao sucesso da Gigabot 2, a Rhodes comprou uma Gigabot 4, que será uma atualização em relação ao seu robusto equipamento atual de extrusora única. Júlio prevê maior facilidade de uso e agilidade, permitindo mãos projetos de prototipagem e prazos mais curtos. Júlio acredita que a força e a eficácia da impressão 3D estão bem estabelecidas e espera que a tecnologia continue influenciando a indústria de móveis.

"[A Gigabot] permite que você projete coisas que não projetaria se não a tivesse; permite que você corra mais riscos, faça mais tentativas. Ele te dá mais munição para acertar o alvo."
Júlio Reis - Designer de Produto Sênior da Rhodes

A integração da Gigabot na Rhodes exemplifica como tecnologias inovadoras podem revolucionar indústrias tradicionais. As percepções de Júlio mostram o profundo impacto da impressão 3D nos processos de desenvolvimento da Rhodes, promovendo a criatividade e possibilitando a exploração de novas possibilidades de design. Olhando para o futuro, a Rhodes está pronta para levar suas capacidades de fabricação a novos patamares com a próxima adição da Gigabot 4. Com sua cabeça de impressão de dupla extrusão, esta avançada impressora 3D permitirá que a Rhodes produza protótipos maiores e mais intrincados, expandindo ainda mais os limites da criação de design. Além disso, ao dobrar sua capacidade de impressão com duas Gigabots, a Rhodes visa acelerar seu processo de prototipagem, permitindo uma iteração e refinamento mais rápidos dos designs de suas cadeiras. À medida que a Rhodes continua a aproveitar as capacidades da Gigabot, a empresa reforça uma história de adaptação e inovação na indústria de fabricação de móveis que não está desacelerando.

Jennifer Dennington

Blog Post Author

Engineering Update – April 2024

It’s been a while since we’ve shared the progress being made by re:3D’s engineering team – June 2023, to be precise. But with the move of our headquarters from Houston to Austin (Texas) underway, it seems like a good time to take stock of where we are and where we’re going in the figurative sense as well.

The Gigabot FFF (Filament) Platform

Filament grinding diagram

re:3D took an intense look at reports of “filament grinding” submitted by our Gigabot user community, taking input from all the spheres within our company. It turns out that “filament grinding” means different things to different people, so our first step was to agree on a common lexicon and definition. We landed on a concise problem statement: “Customers experience poor extrusion performance due to the extruder gear removing material from the filament, “ which captures multiple causes and failure modes or symptoms. The engineering team evaluated, modeled and tested printer components all along the filament path – beginning at the spindle holding the filament spool down to the exit of the extruder nozzle. While recognizing that every user can encounter unique challenges and edge cases, this exercise ranked potential root causes and recommended optimizations in printer slicing parameters and specific improvements in the extruder manufacturing process. We expect these internal improvements and updated slicer profiles to improve overall reliability and print quality.

GB Bed Mesh Sensor 2
GB Bed Mesh sensor
GB Bed Mesh

During check-ins with our customers, we also receive a lot of interest in “automatic bed leveling” – another phrase that can have multiple meanings. We have incorporated an inductive sensor into the Gigabot’s extruder assembly and integrated the necessary software to allow the sensor to quickly map variations in the print bed surface and compensate the z-axis in real time to maintain a uniform nozzle-to-bed distance. This “bed mesh compensation” approach can yield exceptional first-layer results, even on a warped or non-trammed print bed. Our software team is working with the sensor manufacturer to improve the interface and provide a quality user-experience within the Klipper environment. After we finish mesh compensation development on our R&D and internal production printers, we’ll invite the user community to apply to beta test this new feature.

1.75mm filament and bearing cover
1.75mm FDU image
1.75mm Heat Break

Our user community has also expressed a desire for a 1.75mm diameter filament option for re:3D’s Gigabot printers (where our extruders are designed for 2.85mm diameter filament.) In response, we have designed and are testing a conversion assembly to accommodate the smaller filament. The design has been tested for over 300 hours using a variety of filament materials – including flexible filament. It will soon be released as a kit which can be installed by users in the field.

The GigabotX FGF Platform

Crammer on top of a concrete surface

Specific to re:3D’s FGF platforms, the engineering team has focused on improving the performance and reliability of the extruder assembly. The standard ⅝” compression screw has remained unchanged, but the active feeding mechanism (i.e., the ‘crammer’) is getting a full overhaul. Feedstock with poor flowability such as coarse or lightweight plastic regrind and some TPU/TPE resin pellets can have difficulty flowing from the hopper to the extruder via gravity. The crammer provides an auxiliary auger to force these materials into the extruder body. The new design allows for higher and more uniform throughput, and increases reliability by using a stainless steel auger and machined components. Photos and design details, as well as a link to apply to be a beta-tester, are posted here on our User Forum.

GBX 2 Autoload option
GBX 2 Flake loaded by autoload option

In conjunction with the new crammer design, we have been testing an “autoloading” system to supply feedstock from a floor-mounted hopper rather than our normal top-mounted hopper. This system uses compressed air to drive an eductor which pulls and pushes the feedstock into the printer’s extruder via flexible tubing. A detection unit is mounted at the extruder which detects when the feedstock needs replenishing and triggers the compressed air to transport additional flake or pellets. The autoloader is currently being tested on a TerabotX which will be delivered in one of our Gigalab projects. It can operate as a stand-alone system or interface with the Archimajor control board and Klipper firmware to automatically pause printing if a feedstock delivery error is detected.

Coupler spinning

Other efforts underway include designing a more robust coupling mechanism between the extruder motor and the extrusion screw, installing a fourth heating zone to better control the nozzle/die temperature, and a deep-dive investigation into part-cooling for the GigabotX.

Software/Firmware

We are pleased to announce the upcoming release of Klipper Stack v0.5.0. This update represents a significant commitment to enhancing backend operations and ensuring our technology aligns with the latest developments within the Klipper community. Our focus on these upgrades positions us well for the introduction of innovative features in the future.

In pursuit of refining the user experience, we have streamlined the machinery setup process, enabling more rapid and efficient configurations. Enhancements include the introduction of prompt menus for various commands and adjustments to the location and visibility of the emergency stop button to reduce the risk of accidental activation. Furthermore, we have addressed and fixed specific issues such as the omission of certain characters and the disappearance of the virtual keyboard on touch-screen devices after each keystroke, ensuring a smoother and more reliable interaction.

This version also introduces a suite of new features and configuration adjustments. Highlights include the introduction of the ‘exclude objects’ module, which offers the flexibility to remove specific models from multi-model prints directly from the gcode mid-print. The ‘gcode arcs’ module expands movement options beyond the basic G1 move, incorporating G2 and G3 moves for enhanced precision. Furthermore, we have eliminated the homing sequence prior to resuming prints, addressing the issue of potential layer shifts on models.

These enhancements and fixes are part of our ongoing commitment to providing a robust and user-friendly platform, setting a solid foundation for future developments. The update is scheduled to release within a month.

Internal Processes

Internally, the engineering team is implementing processes reflecting re:3D’s ethos of being responsive and transparent to our community. Our engineering change and design processes are maturing to better engage internal and external stakeholders from the beginning of problem identification and requirements definition through operational release and ongoing support. These changes will help focus our resources on those efforts which will have the greatest impact on customer success and map the work against product roadmaps which have been developed to guide the engineering team over the next 12-18 months and beyond. And as an open-source hardware company and proponents of open science, we will be increasing our efforts to share as much of our learnings with the additive community as possible. This includes making our material testing protocols more robust and aligned with industry best practices and hosting an international, monthly FGF Users Group virtual meetup open to anyone interested in printing with pellets or flake.

And More…

Other activities have included improving the printers’ electrical systems and enclosure design. The team also continues to optimize printer software profiles and investigate additional slicing programs available for filament and pellet printing. Finally, additional variants of re:3D’s Gigalab will be presently fielded for evaluations – demonstrating that it is possible to turn waste plastic into usable parts at the point of need through additive manufacturing.

Look for release schedules and more details on all of these engineering initiatives in the coming months. We’ll be sharing via our mailing list, through blog posts and on the re:3D Community Forum. 

Stay tuned, and Happy Printing!

Patrick Ferrell

Senior Engineer