Micah Ganske: 3D Printing and Virtual Reality

“The Future is Always Tomorrow,” the solo exhibition of artist Micah Ganske, was on display in May with the 101/Exhibit Gallery from Los Angeles at the Art Market San Francisco, a massive production in beautiful Fort Mason.  Being the San Francisco-based member of the re:3D team, I was lucky enough to attend the show and see our talented Gigabot-owner Micah’s work in person.

The exhibit revolves around the theme of a futuristic space habitat: a spinning disk called an O’Neill cylinder, with an interior based on the landscape of Centralia, PA, a near-ghost town whose population plummeted due to a coal fire which has been burning underground since 1962.  As Micah puts it, Centralia was “felled by the very technology that once supported its population.”

The exhibit is a mix of paintings, drawings, and sculptures, and the show-stealer is the command center of a spaceship, life-size, with joystick controllers that move.  The entire piece, as well as his other sculptures, is 3D printed, in part by Gigabot and in part by Bold Machines.  This sculpture is paired with an Oculus Rift, and the real fun begins when the headset goes on.  With my hands grasping the controllers of the flight deck, the Oculus Rift transported me into the very world that Micah’s paintings and sculptures depict.  Micah has created a fully-immersive experience, uniting his pieces in one masterfully-crafted virtual world.

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Micah refers to this as “Augmented Virtual Reality,” a combination of Virtual Reality (virtual experiences which replace the real world) and Augmented Reality (virtual experiences incorporated into the real world, laid over your field of view).  The joysticks of the flight deck serve the dual purpose of grounding the viewers in the real world and adding touch to the sensory experience while they soar through the virtual disk landscape and into outer space, while at the same time ensuring that they don’t involuntary tip over in the somewhat disorienting experience.

I was lucky enough to get to try out the experience before the crowds hit, and fortunately so, because once the show got into full swing there was a never-ending line to put on that Oculus Rift headset.   Micah prefaced my experience with the disclaimer that this was his first foray into virtual reality work – it was my first time experiencing it too – but the forewarning was unnecessary; I was completely blown away.

The roughly five minute session felt like an eternity, in the best way possible.  Floating through the air high above the interior of the space habitat, I slowly realized, like the VR newbie that I was, that if I swiveled my head around there was more virtual reality world to explore in my peripheries.  Below my feet, above my head, 180º behind me – I started pivoting around like a madman, trying to soak in as much as I could.  The purpose of the joysticks as a stabilizing handhold became apparent.

As I floated out of the circular landscape into what I can only describe as an airlock, I was sad to be leaving and didn’t want the experience to be over.  To my surprise, I continued floating, a door opened, and suddenly I was suspended, floating through outer space.

This is where I really lost it.  I’m a huge space junkie, and to truly have the feeling of being on a spacewalk was beyond cool.  Ahead of me was a colorful nebula, floating nearby was one of the sculptures of Micah’s exhibit, below my feet was a moon.  In that moment, I realized the potential that VR holds.  This is a technology that will enable people to do and see things that are simply not otherwise possible.  Wannabe astronauts can fulfill their dreams of walking on the moon, paralyzed athletes can climb mountains, aspiring Jacques Cousteaus can dive to the depths of the world’s oceans even with that sinus infection.  Suddenly the technology became an enabler, rather than the introverted crutch I had previously seen it as.

The biggest shock was when the music came to a stop and the headset came off to reveal that I was still standing in the same spot, in the festival pavilion of Fort Mason.  The feeling that came over me was akin to the post-movie depression that so many experienced after seeing Avatar in 3D.  I had truly been on a journey to space and back in just five minutes.  It really was an otherworldly experience.

Micah’s exhibit comes together with a uniting moral perspective: that we need to embrace our “techno-civilization” while also being “smarter about how we live.”  He references Elon Musks’s new Powerwall batteries as an example: they are “something that can change the world today if we are proactive…made possible by smart engineering and responsible industry.”

Although Micah’s exhibit implies that humankind is not able to manage this feat, that we destroy our home planet and are forced to retreat to manmade modules floating in space, he is hopeful.  “In the end I’m optimistic and confident that we will work things out and that the best members of society will make up for the worst,” he says.  “My new sculptures and drawings combine express my hope that we will further use technology to improve and evolve our very selves.  My vision of the future is one of cautious optimism.”

See more about Micah’s work: http://www.micahganske.com/

Check out the 101/Exhibit Gallery: http://www.101exhibit.com/

Read about Micah’s exhibit in the news:

Morgan Hamel

Blog Post Author

The 3D Printing Professional’s Guide to the Comic-Con Floor: What is cosplay and why should I care?

If you’re a 3D Printing news junkie like me, you’ve probably noticed the upswing in articles about prints inspired by comic books. What you may not know is that the act of dressing up as your favorite comic book character for fun has an official name: cosplay. Cosplay is not a new phenomenon by any means. People have been cosplaying for years, if not decades. Cosplay is a huge part of nerd culture, and when I considered the amount of overlap between the geek-o-sphere and the maker movement, I realized it was only a matter of time before I saw these kinds of prints gaining serious traction on my favorite 3D printing industry publications.

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Picture by Photobucket

Having identified this community as a potential sales vertical, the re:3D team ran a booth at Houston’s Comicpalooza to test the waters. Being moderately tapped into the nerd network, I felt I knew what to expect to see at Comicpalooza. However, I noticed that many of my coworkers in the hardware world subscribe to the world of non-fiction, and therefore this culture rooted in fantasy and fiction was foreign to them.

After hearing the same questions over and over all weekend– what is cosplay? why do people dress up like this? why are WE at a comic convention?— I felt some education was in order, not only for my own team, but for the benefit of any industry professionals who might be reading our blog.

This post will hopefully serve as a short guide to those baffled by cosplay and how the community is using 3D printing technology.

“What is cosplay?”

Time for some concrete definitions.

Cosplay happens when a fan dresses up as a character from a comic book, anime, manga, sci-fi or fantasy series. If you’re looking for a technical definition, the best I found online was “The act of gathering raw and ready-made materials to create a 3D object from a 2D reference.” As an article of speech, cosplay can act as both a noun and a verb:

“I will be cosplaying Thor from the Avengers at the Comic Con this weekend.”
“Nice job, man! Your Batman cosplay is amazingly authentic!”

Literally, the word stands for “costume play,” which should give you an idea of the whimsical nature of this hobby. But don’t misunderstand, people take their cosplays seriously. Authenticity is highly important in cosplay. If you can accurately capture and emulate the appearance of a character, it shows you are truly knowledgeable about your fandom. Often, a fan will work on a single costume for months, just to get every detail exactly right. A good cosplayer will never debut their costume before they feel it is “ready” to be seen by other fans. For this reason, the highest compliment you can pay a cosplayer is to ask them one simple question: “Do you mind posing for a photograph for my blog?” The answer will always be, “Of course!” Cosplays are meant to be shared.

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Picture by Photobucket

“Why do people dress up like this?”

The same appreciation that drives a sports fan to wear a jersey to a live match drives a fantasy fan to cosplay. At nearly any celebration of a fandom (such as a midnight movie premier or a viewing party for the premier of a serialized television show) you will see people in cosplay. The idea is to embody your favorite character to show appreciation or deep knowledge of a series. There is, of course, a bit of escapism at play– what Star Wars fan wouldn’t want to be Han Solo for a day?

What’s more, the cosplayer relishes the challenge of creating something seemingly impossible—to recreate a real, human representation of a fictional character. A fair amount of craft and skill goes into cosplay. Many cosplayers are also full-time artists and consider cosplay a legitimate form of artistic expression.

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Picture by Photobucket

However, at the end of the day, I believe people are drawn to cosplay and Comic Conventions because of the community. A sense of acceptance and camaraderie is found amongst cosplayers on the Comic Con floor. It’s nerds admiring and appreciating the dedication of other nerds. You don’t get a sense of cliques– the Trekies don’t butt heads with the Star Wars devotees. Comic Conventions are celebrations of nerd culture. You go to meet friends, see celebrities, purchase collectibles, attend panels, and admire cosplay craftsmanship.

“Why are WE at a comic convention?”

In case it hasn’t been stressed enough, I’ll say it again: authenticity is key in a good cosplay. Because one can achieve a high level of detail and precision in CAD designs, and because many fantasy characters are born from graphic design anyway (i.e. video games, anime, cartoons), 3D printing becomes a very attractive option to the serious cosplayer looking to make a legit cosplay. Another benefit of 3D printing is that you can tinker with designs until you achieve custom fit when it comes to armor and props. What’s more, 3D printing filament is sometimes more affordable per cubic centimeter than traditional cosplay materials.

And, much to my relief, Comicpalooza attendees understood our presence in their space. I couldn’t tell you how many people took one look and Gigabot and said “Wow! You could make great costumes with that thing!” Something that blows my mind about the articles I referenced earlier is that those human-sized prints were made on printers with a relatively small build envelope when compared to Gigabot. The cosplay community recognizes the advantages of Gigabot’s massive build envelope, and I hope they’ll be quick to adopt our technology.

Where do we go from here?

The long and short of it is that 3D printed costumes and props are accurate, affordable, and increasingly common sights on the ComicCon event floor. Though it’s still a bit too early to tell, I think I can say that re:3D’s first foray into the cosplay community was a success. As I have seen our friends in the community sponsor cosplay artists and ask them to appear on their behalf at industry events, I wouldn’t be surprised if we began to see them appear alongside us at nerd culture events. We have all but finalized a booth at a second ComicCon in Austin this coming August, so stay tuned for more details on that as it is finalized. If you missed out on our giveaways at Comicpalooza, this could be your chance to enter to win again!

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Picture by Photobucket

If you would like to chat about 3D printing and cosplay, find me on twitter @rpr_rebecca. I’d love to explore this more with you!

Rebecca Reinhardt

Blog Post Author

re:3D’s Behind the Prints: The Saturn V Rocket

If you were out and about during SXSW Interactive, it’s possible you saw two flightsuited people running around downtown Austin with a nearly 5’ tall model of the seminal Saturn V, the rocket used in the Apollo program to bring human beings to the moon. We turned a lot of heads while toting this print around, which inspired us to share the story of how this Saturn V rocket came to be.

This was a print intended for the July 2014 contest on the r/3Dprinting subreddit. To enter the contest, all someone had to do was print and assemble the rocket and upload a photo of their print to the sub. There were no requirements for size, material or layer height– that’s where the entrant was free to exercise some creativity.

The model, designed by Real Absuridity, was really cool. It was realistic,  detailed, yet tricky in that it had snap-together pieces that required no glue. Considering our roots at NASA, the print struck a chord with our Houston team, and they decided to give it a go.

Our rocket was printed in 5 parts, using PLA plastic. It ended up being 58.5” tall and 8.2 lbs. Here’s a breakdown of what went into each of the 5 pieces:

  • Top piece- 23″ tall, 6″ base. Print time: 29 hours, 41 min.
  • 2nd down from the top- 14″ tall, 6.5″ base. Print time: 36 hours, 11 minutes.
  • 3rd down from top- 10″ tall, 6.5″ base. Print time: 21 hours, 23 minutes.
  • Bottom piece- 13.5″ tall, 6″ base. Print time: 33 hours, 41 minutes.
  • Base section of the platform- 22” x 16” x 6”. Print time: 122 hours, 44 minutes

That’s a total print time of 243 hours and 40 minutes! The print went off without a hitch, despite the length of the print. Lastly, the rocket was painted and decorated to look more authentic, and then we declared it finished.

We got a late start on the contest, and underestimated how long the print would take, so we finished everything after the reddit contest was over. None the less, this was a fun project, we’ll be on the look out for future contests that spark our imagination.

Thanks for reading!

Rebecca Reinhardt

Blog Post Author

2015 re:3D Summer Internships are Live!

Yep, the rumors are true! The next round of re:3D internship openings are live!

The summer we will have a full cadre of interns spanning design, hardware, marketing, and software.  Positions range from fulfilling creative to outright crazy projects and we can’t wait to get started with our newest batch of teammates when the program kicks off June 1st.

Think you’re up for the challenge? Check out all of the positions at: www.re3d.org/careers/ and submit your application here by May 10th!

2014 Summer Design Intern Alberto showing off his Gigabot inspired monocle.

Questions? Contact: info@re3d.org

SXSW 2015: Round up

As the re:3D team wraps up and recovers from what has been an amazing South-by-Southwest experience, we wanted to provide this special update on what we did, who we met, and address some questions people had about re:3D, Gigabot and OpenGB. re:3D’s coverage at SXSW  was primarily during the five days of SXSW Interactive, and came immediately after one of those “too good to pass up” speaking opportunities at the Forbes Reinventing America Summit in Chicago.

While Samantha was speaking on the Forbes panel, the rest of the team was preparing at two venues in Austin: SXSW Create, and SXSW Gaming. As a bonus we were also able to score enough of a footprint at Create to unveil our new Open Gigabot prototype, and launch our Kickstarter on the first morning of SXSW Interactive!

Starting with the most groundbreaking news first, after less than a week of being live, we are now halfway funded on Kickstarter for the new, experimental, Open Gigabot! The Lead Engineer for the OpenGB project, @PatrickFinucane, was on-hand to answer tons of questions, show off the touchscreen in action, and of course, lose his voice like the rest of us after 3 days of talking and sporting those swanky new re:3D flight suits. Stay tuned to the Kickstarter page, as Patrick and the OpenGB team will personally answer some questions that came up about the design process, delivery, and our unique approach to the alpha/beta testing program in the FAQ section and weekly updates.

Taking a step back for a moment, you may have remembered that Gigabot was showcased at SXSW Create for the first time last year. We printed hats and swords, and mostly spread the news that we were now taking orders on our website after a successfully fulfilled Kickstarter campaign. This year was different. We were out in full force in our backyard, engaging with multiple communities in order to better understand our current and future community. In addition to the Open Gigabot Kickstarter launch, our team was invited to a very special event at SXSW Create: A Handathon, organized by the amazing folks at Hanger. Together with some other very well-accomplished 3D printing companies like Lulzbot we printed models of open sourced prosthetic hands provided by our friends at Enabling the Future  to be assembled and presented to kids in need. We met some great pioneers in the prosthetic and 3D printing industries, but it was most moving to see the reaction of the attendees who might not yet have realized this great potential application of 3D printing. Open source movements have never been too shy to tackle big problems in the world, and this is no exception. We’re proud to help this movement grow and evolve with the help of the medical industry around the world.

1.Prosthetic hands printed on Gigabot and decorated by the Toy Joy & Austin Rocks. 2. Instagram of Enable logo printed on Gigabot during SXSW Create

Leading up to SXSW Interactive, we also had the opportunity to print some hands with our friends at Austin Rocks and Toy Joy, who added some local flair to the prints. Gigabot loves showing off in the store front window and generating pre post SXSW buzz. With a half a dozen hands complete, Gigabot took a stroll down Sixth Street to join our Capital Factory sister company, OwnLocal, as well as the Knight Foundation for the 2nd annual News and Schmooze, a mixer for media startups, investors, and companies at Firehouse Lounge. Some great conversations around social impact were generated and we were thrilled to cross paths with our friends at 3D Hubs. The next day Gigabot had the chance to hang out at Speakeasy with our friends at Falkon Ventures, Goldman Sachs, and Collision.

Just two blocks away, the Capital Factory Gigabot was hard at work creating bottle openers live at the Google Next Wave for Entrepreneurs VIP lounge. Todd did an amazing job interacting with influencers including the Huffington Post and Rep Swalwell while Rebecca rocked a roundtable with on women in tech with Rep Morrison.

1. Printing bottle openers live with a view 2. @rpr_rebecca talks to Rep Cathy Morrison at Capital Factory 3. @re3dtodd explains 3D Printing to Rep Swalwell

Now, let’s pick up a 12-sided die and move down the riverfront to the Palmer Events Center. Gaming at SxSW was a new community experience for us. Most of us consider ourselves familiar or even experts on certain genres of gaming, but we were blown away by the diversity of gaming experiences at the event! At SxSW Gaming, we partnered and shared a booth with Advanced Imagination, an innovative company about to release their own Kickstarter for a tabletop3D game, called Boardcraft. Our booth had a combination of a 2D version of the game, “Necro-Virus”, laser sintered models from a $100K+ machine, contrasted with models printing out live on our $9000 Gigabot – a fused deposition manufacturing (FDM) printer that could fit well in a home or local makerspace. It was really great to be exposed to the vibrant and diverse gaming community, and hopefully they enjoyed seeing the Gigabot in action with @gerty.

1. Boardcraft on Gigabot 2. Jim Foreman and @Ernestophocles pose with our 3D printed Saturn IV

Saturday was also a big day for  community engagement. In addition to engaging his fans at SXSW Create, he took time out to facilitate the SXSW 3D Printing Meetup. To hours later, @samanthasnabes shared our Start-Up Chile experience at our first panel titled “Building a Start-Up Ecosystem from Zero“. That night, we had some beers with our Chilean friends at a Start-Up Chile reunion. Along the way, Jimmy Kimmel took a selfie with some 3D printed moais from Sketchfab we gifted to our Start-Up Chile co-panelists.

1. Jimmy Kimmel with the Gigabot Moai 2. @samanthasnabes speaking at SXSW 3. @gerty resting on our 3D printed stool 4. SUP Participant Reunion 5. Gen6 reunited with @samathasnabes & @sergiodelrio

Our last special appearances didn’t include Gigabot, but did involve some big prints. On Sunday morning we were honored to attend the IDA “Business Leaders Breakfast” with Ireland’s Prime Minister to reunite post Web Summit with Enda Kelly and take another selfie on a Gigabot printed chair.

Just a few short hours later, we were out again with a 6 ft, 3D-printed Saturn IV rocket, as well as the world’s largest 3Dprinted Snoo (aka, the Reddit Alien!). Snoo was a big hit at the Reddit/ Daily Dot event, and has consequently been kidnapped in exchange for for Karma!

1. @chief_hacker and @samanthasnabes with Enda Kelley 2. Snoo on his way to his big debut!

To wrap up the event, @katyjeremko attended the SXSW Innovation Awards on behalf of the OpenGB and our Innovative 3-DIY nomination. We didn’t win, but were thrilled to see Project Daniel | Not Impossible labs accept the well deserved award. The next day @larajeremko was at yet another award ceremony where she rocked a pitch at the Austin National Hardware Cup, and our friends at Curb Energy took first place.

1. @larajeremko pitching at the regional National Hardware Cup in Austin 2. @katyjeremko represents OpenGB at the SXSW Innovation Awards

Now that we have had a chance to catch a few hours sleep, we’re taking a moment to followup on the conversations we had and to capture the feedback you provided. In talking to our community, we encountered a few common questions. The most consistent  questions were:

“Why are you doing another Kickstarter?”

The answer lies in our pursuit of continuous innovation. As a small hardware company, it would be easy to get bogged down in finding the best way to manufacture and support the active life of our current product, and be driven only by specific customer suggestions on how we can improve the next models. At re:3D, we have the added challenge and benefit of being a bootstrapped company (in a funding sense). This means that an R&D budget is not won in a boardroom, it is won in front of our customers. Kickstarter is the natural way to get in front of our customer as early as possible with a set of advancements, and ask if this package of features are something the community wants and needs. Judging by discussions with our customers, partners, SxSW conversations, and our current funding level after 7 days on Kickstarter, the early indication is a resounding “YES!”

Another question came up a few times was actually from Gigabot owners and people considering buying our current two-week-lead-time machine:

 “What is the difference between Gigabot and Open Gigabot and can we expect OpenGigabot to be a regular product offering”

Currently OpenGB is an experimental Gigabot that we’re co-developing with the community. As a backer, you’re getting the first edition production model and are part of an exclusive beta-testing group. @MikeBattaglia, our Customer Service Guru and OpenGB Usability Engineer sums this up best from a customer email earlier in the week: “We are definitely not the type of company to leave existing customers in the dust!”

We listen to our entire community as we decide which features to develop and incorporate into our large format printers. Once these offerings are past beta testing and have installation instructions and video tutorials, we will consider migrating them over to our flagship Gigabot offering based what the community prioritizes. We also choose some beta testers from time to time in our community, so if you are interested, please email us at engineering@re3d.org!

This has been a longer update than  anticipated when it was started, but there has been a ton going on in the past week and you need to hear it all. Between SXSW, OpenGB’s Kickstarter, numerous speaking engagements, partnership opportunities, and a constant focus on the well-being of our rockstar employees and customers, I’m personally amazed every day at what we can accomplish together, and can’t wait to see what lies around the corner!

Ernie travels w/Gigabot to share his insights at SXSW, the Austin Mini Makerfaire and UBM Minnesota
@Ernestophocles taking a break on 5th street in Gigabot

Chris Gerty

Blog Post Author

See You At SXSW?!

It’s seems like it was only yesterday since we launched Gigabot on Kickstarter at SXSW in 2013. Two years later, both our Austin and Houston teammates have returned to reflect on the past and look to the future with Gigabot, OpenGigabot, and a few surprise announcements. We’re also honored to be considered for a SXSW Innovation Award and can’t wait to share 3D printed prosthetic hands, board games, a huge Reddit Alien, giveaways and some crazy furniture with the friends we encounter in exhibit halls, tents, bars, hotels, and retail stores. If you plan to attend any of the events below, please say hi or share a Gigabot selfie online!

Here’s a list of where you can expect to find Gigabot and the re:3D gang: 

  • What: SXSW Interactive Panel “Building a Startup Ecosystem from Zero”
    • Where: Hilton Austin Downtown, Salon K , 500 E 4th St
    • When : 3:30pm-4:30pm March 14
    • Connect: #SXSW2015, #ChileAwake, @re_3D, @samanthasnabes, @startupchile
  • SXSW Create 3D Printing Meetup
    • Where: West Pincer Terrace Long Center
    • When : 11am-12pm March 14
    • Connect: #SXSW2015, @CreateATX, #SXCreate, @re_3D, @chief_hacker, @Enablethefuture
  • SXSW Interactive Create Tent: e-NABLE Hand Pavilion Sponsored by
    Hanger Clinic
    • Where: The Long Center for the Performing Arts, 701 West Riverside Drive
    • When : 11am-6pm March 13-15
    • Connect: #SXSW2015, @CreateATX, #SXCreate, @re_3D, @chief_hacker, @patrick_finucane, #openGB, #Gigabot, #innovationawards
  • SXSW Interactive Gaming Festival
    • Where: Palmer Event Center, 701 West Riverside Drive.
    • When : 11am-6pm March 13-15
    • Connect: #SXSW2015, @re_3D, @gerty, #Gigabot, #boardcraft, #necrovirus
  • Toy Joy/ Austin Rocks Live Gigabot 3D printing
  • Google/ Capital Factory Next Wave Entrepreneurs Lounge
    • Where: 1616 W Brazos, 16th Floor
    • When : 11am-6pm 13 March- 15 March
    • Connect: #SXSW2015, @re_3D, @google, @capitalfactory, @GoogleForEntrep, @re3dtodd, #gigabot
  • OwnLocal and Knight Foundation 2nd annual News and Schmooze
    • Where: Firehouse Lounge, 605 Brazos St, Austin
    • When : 6pm -8pm 13 March
    • Connect: #SXSW2015, @re_3D, #gigabot, @knightfdn, #ownlocal, @samanthasnabes
  • Speakeasy/ Falcon Ventures
    • Where: Speakeasy, 412 N Congress Ave
    • When : 6pm -8pm 13 March
    • Connect: #SXSW2015, @re_3D, #gigabot, @falconventures@MikeBattaglia
  • Reddit/ Daily Dot Meetup
    • Where: JW Marriott Room 508 110 E 2nd St
    • When : 3:30-4:30 15 March
    • Connect: #SXSW2015, @re_3D, #gigabot, @reddit, @dailydot, @katyjeremko
  • SXSW Innovation Award
    • Where: Hilton Downtown Austin, 6th floor
    • When: 6pm-8pm 17 March
    • Connect: #openGB, @re_3D, @patrick_finucane, @katyjeremko, @MikeBattaglia, #innovationawards, #sxsw2015

Want to invite Gigabot to your Film or Music Event? Contact info@re3d.org to chat!

SXSW Innovation Award/ Kickstarter Announcement

We’re incredibly flattered to be nominated for SXSW Innovation Award! The other nominees are amazing and we can’t wait to meet them! Check out the clip below to meet the team below and feel free to show your support by using the following social media mentions : @re_3D #openGB #InnovationAwards. Also, check back for a not-so -surprise Kickstarter campaign for OpenGB during SXSW where we will be seeking your feedback on what you want in Gigabot going forward!!

Forever grateful:

 @

Getting a Grip : Part 2

Getting a grip on your 3D printer filament Part 2 by Chief Hacker, re:3D

One of the leading causes of print failure is the filament feeding mechanism. By surveying the literature and leveraging our current experience in hardware development we have identified a gap in the knowledgebase for understanding the mechanics and operations surrounding the extruder drive gear commonly used on FFF type 3D printers.
The goal of this work is to characterize the amount of force that can be generated by a custom machined extruder drive bolt, affectionately named “Jaws”. Details of the engineering development of Jaws is outlined in part 1 of this series. The testing outlined below was performed with a Greg’s Wade’s type extruder for 3mm PLA filament. See Figure 1 below.

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Figure 1. Greg’s Wade type extruder

The first objective of the multipart study is to determine the optimal tension setting for the Greg’s Wade extruder. Tension is adjusted by rotating a pair of screws that compresses a pair of springs that in turn presses the extruder’s idler bearing against the filament. See figure 2A below. This presses the filament into the teeth of the filament drive bolt seen in Figure 2B below.

Figure 2A Tensioning system and force arrow
Figure 2B “Jaws” Filament Drive Bolt

If the tensioner is adjusted too loosely the filament will not fully engage against the teeth of the drive bolt. If the tensioner is adjusted too tightly there may be excessive friction and wear in the extruder. To accurately measure the force imparted to the filament by the extruder we felt it was important to measure the ability of the extruder to push the filament down into the hot-end. Previously, force measurements commonly seen in the literature measure the amount of pull the extruder imparts in the filament coming into the extruder. We felt that by measuring the amount of push we would obtain better real world operating conditions.

The downward force measurement was accomplished by a custom machined fixture that housed a small metal ring outfitted with a threaded tensioning system. The tensioning system is used to slowly grip the filament by turning a screw. As the ring increases its grip on the filament the force is transferred from the filament and onto a compression load cell (THA-100-Q from Transducer Techniques). The load cell was connected to a load cell amplifier (TMO-1 Transducer Techniques) and the analog output from the amplifier was measured by a 12bit A to D daq (USB-1208LS from Measurement Computing). Data was collected at 100 Hz and saved to csv file format. The daq was calibrated using a mass of solid brass and aluminum of known volume. Collected data was processed and graphed using custom Matlab code. The extruder is driven with a 1.68 A 72 oz-in NEMA 17 stepper motor powered at 24 volts. Test setup seen in Figure 3 below.

Figure 3. Tooth engagement, number of teeth engaged and force vectors
Figure 3. Test setup with force measurement

Three trials were performed at four different levels of tensioner adjustments. Tensioner adjustment levels were determined as 2, 4, 8 and 12 revolutions (1 revolution = 360 degrees of rotation) of the tensioner adjustment screw beyond full engagement into its corresponding nut. Example trials are shown in below. Notice in the data graph the period of zero force at the beginning of the trial followed by a gradual increase of force. The force curve shows the peak force imparted into the filament followed by a sharp drop in force where the filament drive gear stripped the filament and filament drive bolt was no longer able to impart a force into the filament. The graphs seen in Figures 4-7 below shows the ability of the filament drive bolt to drive the filament at increasingly greater forces with an increase of tension in the extruder tensioner system.

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Figure 4. Tensioner tightened 2 revolutions
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Figure 5. Tensioner tightened 4 revolutions
Figure 6fixedgrip2
Figure 6. Tensioner tightened 8 revolutions
fig7grip2
Figure 7. Tensioner tightened 12 revolutions

What does this mean for you? With the Greg’s Wade type extruder and the Jaws filament drive bolt we were able to push the PLA filament with over 50lbs of force when the extruder tensioner was advanced 12 revolutions. This researched establishes a baseline measurement for re:3D’s custom extruder bolt which was designed to maximize the grip on PLA filament and help ensure an error free printing experience. This research was conducted at the office of re:3D in Houston Texas.

Matthew Fiedler

Blog Post Author