April Puzzler Solution Revealed!

Below is the solution to the Monthly Puzzler Chief Hacker presented in our April Newsletter. Want to play? You can sign up to receive our monthly publication by submitting your email address in the sign up at the bottom of re:3D.org. Proposed answers are presented on our forum at: https://re3d.zendesk.com/hc/en-us/community/posts/206262336-April-Puzzler

The Question

The April puzzler is another print quality mystery. Take a look at the below pictures of an oversized auger screw originally designed for an automated pet feeder. On one side of the auger there is a blemish in the print yet from another view the print shows an excellent surface finish. What is causing the poor print quality on one spot only?

aprilpuzzler1
aprilpuzzler

The Solution

The winning answer was presented by whosawhatsis who stated both reasons for the problem.

  1. Uneven cooling
  2. Steep overhang with no support

Great job to everyone and keep an eye out for an improved 360 degree cooling feature for the GB3 hot end to give even better printing capabilities!

Happy Printing!

Matthew Fiedler

Blog Post Author

Additive Value for Your Subtractive Manufacturing

Below is Gigamachinist's Steve Johnson's first blog on 3D printing for re:3D's Gigabot fabrication shop.

 Additive Value for Your Subtractive Manufacturing

by Steve Johnson

You may be thinking: “Why would a machine shop need a 3d printer?”

Turns out there are a lot of uses! In my case, we needed to make new fixtures to take advantage of the capabilities of our new 4th axis and the full travel of our machine.  When making fixtures, cost is always a main concern, and making a bad fixture can be expensive in terms of both material and man hours.

By using re:3D’s Gigabot 3D printer, we were able to design our fixture in Solidworks, export the model, and print a full size model of the fixture overnight on Gigabot (no time wasted).

This morning, we tapped the holes for our cam clamps, put the printed fixture into the machine, and checked for clearance and travel issues. In the process we found two issues that we corrected in the solid model, and we are now printing the revised test fixture.

Without the benefit of Gigabot, we may have wasted a 4in diameter by 20in long piece of material, as well as hours of labor. Right now, our only cost has been a few dollars worth of plastic.

This experience has been a great opportunity for me to learn Solidworks and I’m looking forward to using Gigabot again to cut costs, create efficiencies, and to have fun in the shop!

~Happy Printing!

Steve Johnson

Blog Post Author

Drones & Open Source: Partnering with Local Motors

Below is a re-post of content MicheleAbbate hosted on the Local Motors Blog at: https://localmotors.com/MicheleAbbate/lmdrones-re3d-gigabot/

LMDRONES: re:3D Gigabot 

As part of the LMDRONES projects that you can find on Local Motors, we want to welcome re:3D and their Gigabot 3D printer as they join our LM Drone efforts!

lmre3dunite

May 7th was International Drone Day and the Local Motors Teams, from both Vegas and Chandler, paired up with Matthew Fiedler, Co-Founder and Chief Engineer at re:3D, to bring their Gigabot 3D printer to the world’s first drone port, the Eldorado Droneport, in Boulder City, NV.

mfdronedemo

The all day event included open tuning, demonstrations, races, and freestyle flying.  Matt Jackson, Alaric Egli, and Alex Palmer of Local Motors brought a variety of different drones to take part  in the event.  Matthew began printing with the re:3D Gigabot as soon as it arrived, showing it’s potential and usability for creating parts, wings, and even a full size Wing FPV.

fpvdemo

Stayed tuned for what’s next with the re:3D Gigabot which just made its successful journey from Nevada to Chandler, AZ at the Local Motors Headquarters!

gigabotarriveslmchandler

Gigabot arrives at Local Motors Phoenix facility after participating in the International Drone day festivities at Aerodrome near Las Vegas, Nevada. Engineers at Local Motors are excited to train on the Gigabot and start running their first prints!

gigabotatlm

re:3D Gigabot can now be found at the Local Motors’ headquarters in Chandler AZ!

Testing MakeShaper PLA

Below are our notes that reflect our new open source filament testing. ASTM test samples are being created and in the upcoming months you can anticipate a summary on our website about our adventures in 3D printing material science. 

Material Tested: MakeShaper PLA

Manufacturer: MakeShaper PLA

Filament Diameter: 3.00 mm

Color Tested: Orange

Date Tested: 4/01/2016

IMG_2554
IMG_2555

OBSERVATIONS

Ease of use: Working with this filament was very enjoyable. It printed easily, was consistent and predictable. No breakage was noticed. The PLA appeared to be of a high quality.

Appearance: The filament exhibited a pleasing orange tone that even the greatest orange pantone haters on our team found appealing. A slight sheen presented when printed.

Size consistency: Awesome, less than 0.1mm within the roll, however the filament measured 2.87mm, not 3mm

Color consistency: Great, consistent throughout the coil.

SETTINGS

Print temperature: 190-215 C (suggested)/202C was used: nozzle / 60C : bed

Printer Used: Gigabot

Speed: 60 mm/s

Layer Height: 0.3mm

Infill: 15%

Type(s) of print surface used: PRINTnZ

List of test files printed: re:3D’s test files 1, 2, and 3 (logo, vase, and Benchy Torture Test). After April’s UX meeting, it was decided to also print a Moai as a 4th print.

You view watch a video summarizing our testing here:

FINDINGS

Odor: None

Bed adhesion (1: terrible – 5: fabulous!)

  • 5- Great adhesion was achieved with no temperature manipulation.

Stringing (1: lots – 5: none!)

  • 5 –No stringing was observed with our settings.

Shrinkage (1: lots – 5: none!)

  • 5- The filament extruded and cooled with no shrinkage.

Interlayer adhesion (1: terrible – 5: fabulous!)

  • 5- Perfect!
IMG_2556

NOTES:

  • The community is fortunate to have several PLA vendors to select from, however we’ve heard cautionary tales from many of our customers that all PLA is not created equal. MakeShaper PLA boasts that it is a high quality and dependable PLA.
  • Seeing that we offer a limited color selection in our store, we are always eager to test additional PLA sources in order refer customers to other reputable consumer retailers.
  • This material appears to yield consistent, quality prints.
  • Filament size consistency was excellent and no breakage was evident in the 1 kg roll we examined, suggesting it was well mixed.
  • No curling was observed in any of the 4 prints created.
  • We used the mid point of the temperature range that the manufacture provided (190-225C). No guidance was given for settings aside from temperature, so we used the standard Simplify3D profile on wiki.re3d.org.
  • The unboxing experience was well done and the recommendation sheet was professional.
    • A batch number was provided for traceability.
    • Manufacturer recommended settings were easily referenced on the enclosed documentation.

RECCOMENDATIONS:

  • After printing 4 objects in our protocol, I support MakeShaper’s claims that they produce high quality PLA and would recommend it to our customers.
  • Upon review, we would also recommend that we include this filament in our ASTM test sample research.
IMG_2553

Want to chat? Join our forum where we have initiated a thread about our experience!

https://re3d.zendesk.com/hc/en-us/community/posts/206511376-Testing-MakeShaper-PLA

~Happy Printing!

Samantha snabes

Blog Post Author

3D Printing A Superman Hood Emblem

Intern Jacob Lehmann shares on his recent DIY solution to personalize his aging Beetle.

My 3D printed Superman Hood Emblem

By: Jacob Lehmann

I work at re:3D and my job is to figure out and test cool and unique ways to use our 3d printers. I have 2003 VW beetle (and I love it) but some of the aesthetics have been worn and aged poorly over the years. So I had the idea to custom print a rear hood ornament. My amazing bosses thought this was a great idea and helped me to design and realize this idea.

It was hard to pick what exactly I wanted to make for my car. After running through tons of ideas I finally decided that because of the deep sienna blue of my vehicle that a superman logo would look amazing on it. This is a picture of my car after I peeled off the old rusty and broken VW emblem.

before
final

First I designed the hood emblem in a free Cad software called Onshape. You can access the tool at this link: https://www.onshape.com/ if you are interested. 

After slicing the file for printing, we put it on the Gigabot and watched it come to life!

startingprint
halfprint
finishedprint

And then we tested it on my car.  After looking at it closely, I decided I wasn’t happy with the size and printed a second to fill up the space better.

testingprint

Before we started we knew that the final solution wasn’t going to be in PLA.  In the Texas summer sun, thermoplastics such as PLA warp when left in a car, let alone on the boiling hood. Although this material is perfect for 3d printing because it melts at roughly 190+ Celsius, that very feature makes it hard to use outdoors, inside of engines, or pretty much anywhere that gets hot.

Thankfully our friends at Deep in the Heart Art Foundry (who own some of our Gigabots and use them in their lost wax casting) were more than happy to help us cast an alternative. We originally wanted to cast the piece in bronze and patina it, but they suggested that it would look better and be much lighter to cast it in Stainless steel. You can check out some of their amazing works of art here http://www.deepintheheart.net/. Here is the piece once we got it back (with a little bit of polishing).

unpolished

And after I finished polishing and sanding the piece.

polished

Here is the finished stainless steel piece next to the smaller PLA prototype.

Now all that was left to do was mount it on my vehicle. After cleaning the surface of my rear hood and the backside of the piece with some alcohol, and removing all the dust and grime, I placed some 3m double-sided tape on my car. NOTE: my bosses were concerned for my and other driver’s safety and have since purchased industrial epoxy.

3mtape

And finally, the beautiful hood emblem is complete and placed on my car. Now I can drive around fighting DC supervillains as much as I want.

final

Happy printing!

Jacob Lehmann

Blog Post Author

@jacobelehmann

You’re Invited: 3D Printing @ Sea!

Recently, one of our customers (and owner of Cruise Planners) invited us to support a 3D printing cruise. We are honored to participate and can’t wait to spend three days with you during this exclusive experience!

3datsea

About the Event

3D at Sea is the first of it’s kind 3D Printing Workshop and Seminar at Sea. This Workshop will feature 3D Printing Experts both teaching and speaking on a variety of relevant topics. There will also be opportunities for community impact work in Cozumel, in addition to general fun and networking!

Whose Invited

Anyone with a passion for 3D printing is welcome to join us on the Carnival Liberty out of Galveston on 10/8/16! Pam, the organizer, is also accepting applications to speak or teach a class until May 5th. You can share your interest on Facebook at: www.facebook.com/3datsea/  or email Pam directly at: pam.stewart@cruiseplanners.com.

See you soon?!

Samantha snabes

Blog Post Author

Filament Testing – Scorpion Flexible Nylon by Black Magic 3D

Below are our notes that respect our new open source filament testing. ASTM test samples are being created and in the upcoming months you can anticipate a summary on our website that reflects our adventures in 3D printing material science. 

Material Tested: Scorpion Flexible Nylon

Manufacturer: Black Magic 3D

Filament Diameter: – 2.85mm

Color Tested: Natural

Date Tested: 4/06/2016

IMG_2511

OBSERVATIONS

Ease of use: Those new to 3D printing may want to budget extra time when printing with Scorpion as it takes a little manipulation to perfect the temperature & retraction settings.

Appearance: The natural filament was clean and consistent. Prints matched filament color & opacity.

Size consistency: Awesome, less than 0.1mm within the roll.

Color consistency: Great, consistent throughout the coil.

IMG_2507

SETTINGS

Print temperature: 230-235 C (suggested): nozzle / 60C : bed

Printer Used: Gigabot

Speed: 50 mm/s

Layer Height: 0.3mm

Infill: 15%

Type(s) of print surface used: PRINTnZ with 3M Blue Painter’s Tape and 2 coats of Elmer’s Glue Stick

List of test files printed: re:3D’s test files 1, 2, and 3 (logo, vase, and Benchy Torture Test)

You view watch a video summarizing our testing below:

FINDINGS

Odor: None

Bed adhesion (1: terrible – 5: fabulous!)

  • 4- Great adhesion could be achieved, but required two coats of PVA glue stick, painter’s tape, and the highest heat setting suggested for the bed and nozzle.

Stringing (1: lots – 5: none!)

  • 4 -Stringing was observed across lettering, however doubling the retraction settings eliminated the problem.

Shrinkage (1: lots – 5: none!)

  • 4- Some curling was observed on corners of logo after removal. It is suggested that the print be allowed to cool down on the bed before taking it off.

Interlayer adhesion (1: terrible – 5: fabulous!)

  • 5- Perfect!
IMG_2508

NOTES:

  • A flexible nylon offers a lot of possibility to the 3D printing community
    • This filament appears to overcome concerns that both flexible and nylon materials are difficult to use.
    • With the right settings and adhesion hygiene, this material appears to yield consistent, quality prints.
  • NOTE: this filament required 2 coats of Elmer glue stick on Blue Painter’s tape applied over a heated bed, using the max range of bed and nozzle heat settings
  • Filament size consistency was excellent.
  • Curling was observed with only 1 coat of glue stick and was also seen after print removal when the bed was still warm.
    • It is recommended that the bed be allowed to cool before removal to mitigate curling after print completion.
  • The best testing outcomes were observed at the highest temperatures settings (235C -nozzle, 60C- bed) and using the speed (50mm/s) that the manufacture provided. No guidance was given for retraction, which we found we needed to double or standard setting in order to eliminate stringing across lettering.
  • The unboxing experience was well done and the recommendation sheet was very useful. 
    • No date stamp for production was listed, however a batch number was provided for traceability.
    • Manufacturer recommended settings were easily referenced on the enclosed documentation.
IMG_2510

RECCOMENDATIONS:

  • This filament is extremely impressive and more than exceeded expectations due to past expereinces working with nylons and flexible materials.
  • Upon review, we would highly recommend that larger, more complex prints be created to further investigate the potential this exotic, and much needed material provides.
IMG_2368

Want to chat? Join our forum where we have initiated a thread about our experience!

https://re3d.zendesk.com/hc/en-us/community/posts/206375086-Testing-Scorpion-Flexible-Nylon-on-Gigabot

~Happy Printing!

Samantha snabes

Blog Post Author

February Puzzler Solution Revealed!

Below is the solution to the Monthly Puzzler Chief Hacker presented in our February Newsletter. Want to play? You can sign up to receive our monthly publication by submitting your email address in the sign up at the bottom of re:3D.org. Proposed answers are presented on our forum at: https://re3d.zendesk.com/hc/en-us/community/posts/205859796-February-Puzzler

THE SOLUTION

Here are the two reasons you will see a visible mark between processes.

Answer #1. If the SECOND process settings (upper part of the print) has “First layer height” that does not match the layer height for the FIRST process there will be an odd layer thickness visible on your print. Make sure the first layer height and first layer speed for the SECOND process are set to 100%

Answer #2. When setting the “Stop Printing at Height” make sure the dimension is an even multiple of your layer height. Don’t forget to account for any changes in layer height if you enter a value other than 100% for the FIRST process “First Layer Height”!

Since Darrel had one of the two correct answers we will be sending you half a spool of filament 🙂  Just kidding Darrel! Thanks for playing and keep an eye out for next month’s puzzler.

Happy Printing!

Matthew Fiedler

Blog Post Author

@chief_hacker

Filament Testing: Printing with Algae!

Below are our notes that respect our new open source filament testing. ASTM test samples are being created and in the upcoming months you can anticipate a summary on our website that reflects our adventures in 3D printing material science. 

Material Tested: 3D Fuel/Algae-Fuel

Manufacturer: Algix3D

Diameter : – 2.86mm

Color Tested: Slightly green/brownish

Date Tested: 2/28/2016

IMG_2133

OBSERVATIONS

Ease of use: A little tricky due to the brittle nature of the filament, however, once you get started you are good to go!

Appearance: Aesthetic, reflects sustainability, “rough texture”, definitely not smooth!

Size consistency:  Average, within .1mm within roll.

Color consistency: Great, consistent throughout roll.

IMG_2134

SETTINGS

Print temperature: 175 C (nozzle) /55C (bed)

Printer Used: Gigabot

Speed: 30mm/s

Layer Height: 0.3mm

Infill: 35%

Odor: Earthy, smells like algae

Type(s) of print surface used: Print n Z

List of test files printed: re:3D’s test files 1, 2, and 3 (logo, vase, airplane gear piece)

 You can watch a video  summarizing our testing:

FINDINGS

Bed adhesion (1:terrible-5:fabulous!)

  • 4 (could have been optimized by adjusting cooling/ temperature)

Stringing (1: lots -5: none!)

  • 4 (could have been optimized by adjusting speed/ temperature)
    • Only noticed slight stringing in vase

Shrinkage (1:lots-5: none!)

  • 5-None!

interlayer adhesion (1:terrible-5:fabulous!)

  • 5- Perfect!
IMG_2155

NOTES:

  • A renewable filament that reduces the environmental footprint of production is highly appealing to the 3D printing community.
  • The biggest limitation is the brittle nature of the filament, making initial setup a little tricky. NOTE: this filament was tested 4 months after receipt, however, for many users a 4 month shelf life is ideal.
  • Filament size consistency was about on par with most filament.
  • Little delamination and no curling was observed.
  • All testing was conducted at the lowest temperature and speed range that the manufacture provided. It’s likely that the outcome would have been even better had the mid to high range temperature ranges had been explored.
  • The unboxing experience was well done and the recommendation sheet was professional.
  • We appreciated the made in America reference, and date stamp of quality control on the box and insert.
  • Manufacturer recommended settings were easily referenced on the enclosed insert

RECCOMENDATIONS:

Not all users may appreciate the aroma, however if you are looking for a more sustainable 3D printing alternative and doesn’t require a smooth surface, this materials may be for you!

Want to chat? Join our forum where we have initiated a thread about our experience!

https://re3d.zendesk.com/hc/en-us/community/posts/206091996-TESTING-3D-FUEL-ALGAE-FUEL

~Happy Printing!

Samantha snabes

Blog Post Author

Made in America: Rapid Prototyping with “GiggleBot”

Below is a re-post of a blog women-owned small business Acoustics First wrote about their Gigabot experiences in Virginia. More information about Acoustics First is available on their website. We’re also honored to feature them on the stories tab of our website. The original post can be accessed here. 

As the summer of 2015 winds down, we here at Acoustics First thought we’d share our latest acquisition with our readers.

Meet the Gigabot™ (or as we call him “Gigglebot”).

This amazing large format 3D printer was developed by re:3D, an outstanding company whose principals come from varied backgrounds which include experience working at NASA, among other things.
The eight cubic foot build volume of this beast makes it ideal for the rapid development and prototyping of our industry leading sound diffusers! We look forward to using this wonderful device on many projects in the years to come.
Watch this short video we made during one of our trial runs. For this calibration test we chose to print a scaled down version of our patented Model D Art Diffusor®.

Who said manufacturing was boring?!?!

~Acoustics First

info@acousticsfirst.com