3D printing with flexible filament

3D printing with flexible filament

The advantages of flexible filament

Printing with an FDM 3D printer offers more and more possibilities. In the past, PLA filament was by far the most widely used material, because it is cheap and very easy to print. Now we see the use of other types of filament increasing in the market. Due to the ease with which we can 3D print models and parts ourselves, there are increasing demands on the material. The models are used for more and more applications, for example small series of products or machine parts. In short, the 3D printer market is developing rapidly and there are now various types of filament (printing material) on the market, so the right material can be used for each application.
The dddrop 3D printers are specially developed with an open system and offer complete freedom of choice in printing material. This means that you are not only free to choose your supplier, but also the type of material you want to print. The closed housing and heated print bed make it possible to create models from all kinds of materials. In this article we highlight the flexible filament TPU.

Flexible filament

Flex filament is a collective name for all the flexible filament on the market. These filaments are also known by the name TPE (thermoplastic elastomer). There are different types of TPE, of which thermoplastic polyurethane (TPU) is the most commonly used among 3D printer filaments. As the name suggests, this material is elastic in nature, so the plastic can be easily and extensively stretched and bent before breaking. In addition, it has a high temperature resistance and thus can be used in high temperature environments. The material is best described as the perfect balance between hard plastic and silicone. It is a combination of the beneficial properties of both materials, making TPU flexible, but dimensionally stable, unbreakable, dust resistant and barely scratchable. In addition, this material can be completely transparent.

TPU filament is easy to print

Of the flexible materials, TPU is the easiest to print, because it is relatively a hard flex filament. The “softer” the flex filament, the harder it is to print. Using a special soft spring to guide the filament to the print head, the right print settings and a clean nozzle, it is easy to print a flexible product with TPU.

Applications of TPU filament

TPU is used for shoe soles, for instance, but also for pads or other shock-absorbing applications. We also see many applications for closing off certain sections by means of, for example, cover rings

A frequently asked question is whether it is possible to print with rubber. Printing with rubber is not possible, but TPU or other flex filaments can be used for rubber-like solutions.

Exploring Carbon Fiber 3D Printing: Strength Meets Lightweight Precision

Exploring Carbon Fiber 3D Printing: Strength Meets Lightweight Precision

The advantages of the material PET-G Carbon

In the ever-evolving domain of additive manufacturing, the innovation of carbon fiber filaments has marked a significant milestone, paving the way for many industrial applications. Utilized in a carbon fiber 3D printer, this specialized filament embodies a unique blend of carbon fibers and thermoplastic materials, tailored meticulously for Fused Deposition Modeling (FDM) technology. When extruded through a carbon fiber 3D printer, the filament melds into a solid structure, embedding the carbon fibers within, thereby imparting a remarkable strength-to-weight ratio to the printed parts. This distinct characteristic of carbon fiber 3D printing is a linchpin in applications where both durability and weight are critical determinants. The ensuing sections delve into the intricacies of PET-G Carbon, the ease of printing with this material, and a deeper exploration of its applications across various industries.

Advantages of PET-G Carbon

In the realm of FDM 3D printing, PLA (Polylactic Acid) emerges as a well-known and frequently utilized printing material, primarily due to its cost-effectiveness and relatively simple usability in 3D printing endeavors. However, PLA exhibits certain limitations, notably its lackluster heat resistance, which could pose challenges in specific applications. Fortunately, the continuous innovation in 3D printing materials has birthed a plethora of options, catering to a wide array of application needs.

Among the notable materials is PET-G Carbon, which stands as a robust contender in the lineup of 3D printing materials. The dddrop 3D printers, in particular, have been meticulously engineered to offer a broad spectrum of material choices, thanks to the dddrop open filament policy. This policy transcends the mere freedom of selecting any filament supplier; it extends to the liberty of choosing any material, thereby enriching the 3D printing experience. The encapsulated casing with temperature control, coupled with a heated printer bed, empowers the creation of models from a multitude of materials, thus expanding the horizons of what can be achieved with 3D printing.

In this segment, the spotlight is cast on PET-G Carbon, exploring its core attributes and the advantages it brings to the table. The fusion of carbon fibers with the base material PET-G culminates in a filament endowed with enhanced qualities. Carbon fiber, known for its remarkable strength, imbues the filament with heightened sturdiness and rigidity. This augmentation in hardness significantly mitigates the risk of scratches or other forms of damage when a 3D printed model interacts with other objects. However, it’s crucial to note that the increased hardness makes the material more susceptible to breakage upon impact compared to regular PET-G filament.

PET-G, in its pristine form without the carbon fibers, is famously recognized in the form of PET-bottles used for housing sodas. This form of PET-G exudes a shiny appearance; however, the infusion of carbon fiber alters its aesthetic to a matte and anthracite hue, which could be a desirable trait for certain applications.

In the subsequent sections, the ease of printing with PET-G Carbon and its alternative for larger models, PA Carbon, will be explored further, diving into the practical aspects of using these materials in a carbon fiber 3D printer.

Understanding Carbon Filament

Carbon filament, specifically carbon fiber-reinforced polymer, is at the heart of the enhanced performance characteristics seen in certain 3D printing materials. In the case of carbon filled filament, tiny fibers are infused into the base material, in this instance, PET-G, to elevate the inherent qualities of the material. Carbon fibers are renowned for their outstanding strength, which renders it considerably more robust and rigid when incorporated into the filament.

Integrating carbon fibers does more than enhance the strength; it also significantly reduces the risk of scratching or other forms of damage when a 3D printed model interacts with other objects. This is particularly beneficial in applications where the model may be subject to physical contact or abrasion. However, it’s essential to note that while the hardness increases, the material is more prone to breaking when dropped than regular PET-G filaments. This trade-off needs to be considered based on the specific use case and the environment in which the printed object will be used.

The aesthetic transformation that accompanies the addition of carbon fiber is also noteworthy. Unlike the shiny appearance of traditional PET-G, the carbon-filled variant takes on a matte and anthracite-colored finish, which might be preferable for applications seeking a sleek, professional look.

carbon fiber 3d printer 2

The mechanism behind incorporating carbon fibers into the filament is a fine-tuned process that ensures even distribution of the fibers within the material, thus ensuring consistent properties throughout the printed model. The carbon fibers are not merely surface additives; they become an integral part of the material structure, significantly enhancing its performance metrics.

Ease of Printing with PET-G Carbon

Transitioning to a specialized filament like PET-G Carbon comes with its share of considerations, yet, the learning curve is not steep, making it a viable option for a range of users. One of the appealing aspects of printing with PET-G Carbon is that the printer settings required are largely similar to those used for standard PET-G filament. This familiarity in settings simplifies the transition and allows users to leverage their existing knowledge while exploring the enhanced capabilities of PET-G Carbon.

The working temperature for PET-G Carbon stands at 80°C, a parameter that ensures the material does not warp, thereby aiding in the retention of the shape of the printed models. This is a significant advantage, especially in applications where dimensional accuracy and structural integrity are crucial. The non-warping characteristic also reduces the likelihood of printing failures, saving both time and material resources.

Despite the ease of printing, it’s important to acknowledge that PET-G Carbon is an abrasive material. The embedded carbon fibers, while enhancing strength, also increase the wear on the brass nozzle of the printer. This is a common challenge faced when printing with abrasive materials and may necessitate the use of a hardened or stainless steel nozzle to mitigate the wear and prolong the lifespan of the printer nozzle.

The journey of exploring PET-G Carbon accentuates the versatility and growth within the 3D printing material spectrum, highlighting the potential to achieve strong, durable, and aesthetically pleasing prints with relative ease. As we transition to discussing PA Carbon in the ensuing section, the narrative continues on the path of unveiling the robust material options available for a carbon fiber 3D printer, each with its unique set of advantages and considerations.

PA Carbon

When the objective is to print larger models, the properties of PET-G Carbon may fall short in meeting certain requirements. In such scenarios, PA Carbon emerges as a viable alternative that holds promise for delivering the desired performance characteristics. The PA in PA Carbon refers to polyamide, a type of polymer that is known for its excellent mechanical and thermal properties.

One of the prominent PA Carbon filaments is Novamid® ID 1030 CF10 from DSM, which is a concoction of PA 6/66 along with carbon fiber. The incorporation of carbon fiber into the polyamide matrix elevates the strength, stiffness, and hardness of the filament, making it a more suitable candidate for larger models. Furthermore, the carbon fiber infusion results in a filament that is lighter and offers commendable resistance to collision and heat, properties that are often requisite in larger 3D printed models.

The heat resistance is particularly noteworthy as Novamid® ID 1030 CF10 can withstand high temperatures without distorting, a feature that is paramount in applications where the printed parts may be exposed to elevated temperatures.

However, it’s worth mentioning that the journey of printing with PA Carbon, particularly Novamid® ID 1030 CF10, comes with its share of challenges owing to its high-tech nature. Unlike PET-G Carbon, PA filament requires a more refined set of print settings to achieve optimal results. This necessitates a deeper understanding and perhaps a more experienced hand at managing the print parameters to ensure successful prints.

The team at dddrop has conducted extensive testing to derive the correct print settings for Novamid® ID 1030 CF10, easing the path for users. The use of Magigoo PA, for instance, is recommended for perfect adhesion to the 3D printer bed, ensuring that the prints remain stable throughout the printing process.

In a nutshell, PA Carbon, and specifically Novamid® ID 1030 CF10, opens the doors to printing larger carbon models with a carbon fiber 3D printer. While it may demand a higher level of expertise and attention to print settings, the payoff in terms of strength, heat resistance, and size capabilities is significant. Through the lens of PA Carbon, we continue to explore the expansive realm of carbon fiber 3D printing, each material bringing its unique set of advantages to the fore, and catering to a broad spectrum of application needs.

Applications of Carbon Fiber 3D Printing

The use of carbon fibers in 3D printing expands its applications due to its strength and reduced weight.The use of carbon-filled filaments, such as PET-G Carbon and PA Carbon, opens up a world of possibilities in fields where these characteristics are crucial.

One of the most vibrant arenas where carbon fiber 3D printing shines is in the construction of drones. The strength-to-weight ratio is crucial for drone components, as it directly impacts the flight efficiency and durability of the drone. Carbon fiber 3D printed parts provide the requisite strength while keeping the weight minimal, thus contributing to enhanced flight times and overall performance.

carbon fiber 3d printer

The quest for lightweight yet strong materials is incessant in the automotive industry. Carbon fiber 3D printing aligns well with this pursuit, offering a means to fabricate robust, lightweight parts capable of withstanding the rigorous conditions inherent in automotive applications. From structural components to aesthetic enhancements, the utilization of carbon fiber filaments adds a new dimension to automotive design and manufacturing.

The prosthetics field also benefits immensely from carbon fiber 3D printing. Creating prosthetic limbs and supports that are both lightweight and strong can significantly enhance the comfort and mobility of individuals who rely on these devices. The customizable nature of 3D printing and the superior properties of carbon fiber filaments pave the way for personalized, durable, and functionally efficient prosthetic solutions.

Conclusion

Exploring carbon fiber 3D printing unveils a world full of potential and new ideas. Through the details of PET-G Carbon and PA Carbon, we’ve seen how carbon fiber 3D printing becomes a strong player in modern manufacturing. By blending carbon fibers with plastic materials using a carbon fiber 3D printer, we open a door where strong materials can also be lightweight. As different industries grow, the need for such materials increases. Carbon fiber 3D printing steps in to meet these needs, showing its worth in various fields like drones, cars, and prosthetics. The dddrop 3D printers show us the beauty of having a variety of material choices, pushing the spirit of innovation in the 3D printing world further. This freedom to choose and experiment with different materials showcases a future where we can tailor materials to specific needs, enhancing performance. Our journey into carbon fiber 3D printing is just a glimpse into what’s possible, setting the foundation for more discoveries in materials and printing technologies. Each layer we print is a step towards a future where the limits of what a carbon fiber 3D printer can do are constantly pushed further. This story of carbon fiber 3D printing shows us the exciting transformations additive manufacturing can bring, inviting us to a future full of endless opportunities.

How to prevent 3D print ghosting

How to prevent 3D print ghosting

What is ‘ghosting’ and what can I do to prevent it?

The side of 3D printed models are made up of hundreds of different layers. When everything is working optimally, these layers appear to be one because of the smoothness of the surface. But when something goes wrong during the placement of the layers, it is clearly visible on the outside of the print. The incorrect layers are presented in the form of lines or ridges on the side of the model. This can have several causes and one of them is ghosting. In this blog we will explain why ghosting occurs and how it can be avoided.

We speak of ghosting when the lines or ridges seem to repeat themselves across the surface of the 3D model. The imperfections created by ghosting appear after the curve and then slowly disappear. Usually the lines are quite subtle, hence the term “ghosting”. As a matter of course, one always strives to print the model as neatly as possible. Ghosting can make the appearance of a model less beautiful.

How ghosting occurs

Ghosting is caused by vibration. In most cases, it happens when moving parts, such as a print head, have to suddenly change direction of movement. Therefore, it often happens with prints that contain sharp corners. Most printers have a uniform print speed, which means that the print head moves past these corners at the same speed and amount of material. But if it suddenly has to change its direction of movement, the material is printed too fast and does not spread out nicely. In addition, the mass of the print head combined with the rapid change in direction causes vibrations that are reflected in the model. Once these vibrations are gone, the layers are smeared evenly again.

How to prevent it?

To prevent ghosting, it is crucial to be efficient with the speed of the print head and the material. This means slowing down the print head in time and gradually, and printing less material before changing direction. For example, before a sharp turn. After the turn, the speed should be built up again gradually to avoid vibrations in the print head.

RAPID ONE

At dddrop we are constantly improving and optimizing the 3D printing process. When developing the new dddrop RAPID ONE, control over the speed of the print head was a key starting point. This resulted in perfect acceleration and deceleration of the print head, ensuring neat 3D print models and efficiency in print speed. The overall print speed can be increased significantly without compromising the quality of the 3D model, even those with sharp corners.

How to maintain your 3D-printer?

How to maintain your 3D-printer?

Maintaining your 3D printer

The first hours of printing are behind you and by now your 3D printer has become indispensable to your development and production process. Before you leave for home in the evening, you want to get the printer up and running quickly so that your prototype is waiting for you in the morning. There is nothing more frustrating than seeing an error and having your 3D printer become unusable. A 3D printer is a machine and (as with all machines) it is important to maintain it properly and on time. In this blog you will read practical tips and we will show you the possibilities dddrop offers in terms of service and maintenance.

The right environment for your 3D printer

The most important aspect for a long life of your 3D printer is the environment in which it is located. An office environment is preferred so that dust, dirt and other environmental factors cannot affect the printer. When a 3D printer is in a production environment, the risk of dust and other debris getting into the machine or onto filaments is significantly higher. This can, for example, cause the nozzle to become clogged as dirt collects here. In addition to dirt and dust, the ambient temperature is also important for the 3D printer. A room temperature (between 21ºC and 24ºC) results in the best prints and extends the life of the 3D printer.

Cleaning your 3D printer

You can place your 3D printer in a very clean environment, but you will still need to make sure that the 3D printer itself is clean as well. Thoroughly clean a clogged nozzle for the best results and life of your nozzle. Use a special stainless steel nozzle for rough fibers (such as PET-G Carbon). Also clean the printer bed thoroughly after each print, using an appropriate cleaning agent. Be sure to empty the filament waste bin regularly, and don’t forget any filament that has fallen to the bottom of the printer housing.

Maintenance schedule for your 3D printer

In addition to the things you can do yourself, it is also important to have the technical aspects of your printer checked. The dddrop 3D printers have a built-in maintenance schedule. This schedule is based on the number of print hours. When the 3D printer reaches 2500 hours, a maintenance key will appear on the screen. This is the time to give your printer a maintenance check. This maintenance can be performed by dddrop. Some parts are then replaced as a precaution so that your printer does not stall at a time when you do not expect it. Maintenance is also recommended at 5000, 7500 and 10,000 print hours, to replace other wear parts.

3D printing with support material

3D printing with support material

When do you need to 3D print with support material?

The great advantage of 3D printing is that it allows you to print very complex models that are difficult to produce with other techniques. For example, think about printing an overhang. Because 3D printed parts are made up of layers, you always need an underlying layer to build on. So depending on the complexity of the 3D model, you may need to work with supporting structures. Below we explain the possibilities.

An FDM 3D printer can (in most cases) print an overhang with an angle below 45° without the need for support. A tip here: reduce the layer height, for example from 0.2 to 0.1mm. The printer will now produce twice as many layers, allowing the printer to take smaller steps when creating an overhang. For angles greater than 45°, it is advisable to support the 3D model. This can be done in three ways:

  • Support with the original material
  • Supporting with PVA filament
  • Supporting with PVA+ filament

Supporting with the original material

We’ll start with the easiest and fastest way to support your 3D print. Moreover, it is the only option if you print with one extruder. In this method, the required support is printed from the same material as the model. This method works easily because you only need one material. A slicing software package, such as Simplify3D, can generate these support structures. Note that it is important not to use too much support material, because support structures of the same material are more difficult to remove from the model than the other options.

Supporting with PVA filament

There are special support filaments available that are completely soluble. PVA is one of them. To print with PVA, you need a 3D printer with a dual extruder.

PVA stands for polyvinyl alcohol and is a soft and biodegradable polymer that is very sensitive to moisture. When PVA is exposed to water, it will dissolve. Therefore, it is perfect as a carrier material for 3D printing. After printing, the filament can be easily removed by dissolving it in cold or lukewarm water. PVA is often used in conjunction with PLA filament, but is now increasingly being applied to other filaments such as PET-G. In addition, there are several new modifications that make it possible to use PVA with higher temperatures. For example, we are talking about PVA+.

Supporting with PVA+ filament

Previously, HIPS was mainly used as a support material for printing in ABS. With the advent of PVA+, HIPS is used a lot less. The reason for this change is that HIPS must be dissolved in limonene. This is a difficult to obtain, chemical. Therefore, HIPS is often replaced by PVA+ (modified PVA), a fiber that is easily soluble in water – just like PVA. PVA+ also requires the use of a dual extruder.

The major advantage of printing with support material is that it is easily removed without leaving parts behind or damaging the 3D model. A disadvantage is that support filaments are often more expensive than the base filament and can only be printed on a 3D printer with a dual extruder. dddrop also sells its own support material for the best printing results.

3D design and 3D printing

3D design and 3D printing

How to design and print a perfect 3D model?

That engineer is a special and great profession needs no further explanation. All objects around us were once developed by an engineer. For years we all produced mainly with the well-known techniques such as mill-turning or injection molding. Meanwhile, the 3D printer has made its appearance in the manufacturing industry and this also requires a change in development: designing for a 3D print requires a new way of thinking.

With traditional techniques, development usually starts with a piece of material from which parts are removed until the desired product is achieved. With 3D printing, development begins with an empty space. This empty space is the engineer’s new starting point, as the 3D model is built from layers. What does this mean for the design and printing process?

Making a 3D model

First of all, we require a 3D drawing of the product or part. There are several 3D CAD software packages available for creating the 3D design, like SOLIDWORKS. You can learn how to draw simple models relatively quick, there are various trainings available that teach the basics.

Make it 3D printable

When the 3D drawing is ready, it needs to be converted into a printable 3D file: a so-called .STL file. Several software packages, like Simplify3D, convert 3D drawings into a layer-based model. You basically don’t need to do anything about it, but of course it is possible to adjust some settings to tailor it to -for instance- the material (filament) you’ll be using.

Important aspects to take into account during the design and printing process are:

Thin walls

It sometimes happens that models are scaled to a different size. When scaling down, it could happen that the walls become too thin to be printed. Most 3D printers have a set nozzle (printer head) size with a diameter of 0.4mm. Although this works fine for most models,
problems could arise when layers smaller than the nozzle size need to be printed. When a wall of 0.2mm has to be printed with a 0.4mm nozzle, this thin wall will not be shown in the Simplify3D preview and not be printed. Read more about printing thin-walled products.

Tip: always scale in the CAD program (instead of the slicing software) for the best result.

Support material

Support materials like PVA or PVA+ are often used with 3D printing. These filaments are soluble and enable printing hollow or other complex forms. The angle in which a 3D printer can work without support material is 45 degrees. Every lower angle, so from 0 until 44 degrees, has to be supported. Also when printing for instance a screw thread, support material is required. Read more about printing with support material.

Assemblies

Complete assemblies can be 3D printed in one go, provided that the printer bed is big enough for it. To print an entire assembly, it’s important that the complete assembly is saved as one .STL file.

Bridging

A 3D printer can easily print bridges up to 5 mm. For bridges from 5 to 15 mm, some adjustments in the slicing software are required. The big advantage of printing with plastic filaments, is that it will tighten when it cools down, as the material shrinks a little.

Tolerance

When printing two parts that need to fit together, like a bolt/nut construction, you need to take the shrinking of the material into account. It’s usually enough to use a tolerance of ±0.1mm, but this can differ per model.