High-performance polymer 3D printing – Open-source liquid cooled scalable printer design

Andreas Hagerup Birkelid,Sindre W Eikevåg,Christer W Elverum,Martin Steinert

doi:10.1016/j.ohx.2022.e00265

Andreas Hagerup Birkelid, Sindre W Eikevåg + Show 2 more

Open Access

https://doi.org/10.1016/j.ohx.2022.e00265

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Journal: HardwareX	Publication Date: Jan 10, 2022
Citations: 2	License type: cc-by

Affiliation: Norwegian University of Science and Technology

Abstract

To print high-performance polymers, a stable running printer that can reach high temperatures is needed. There is currently a lack of low-cost solutions that allow manipulation of process parameters and expansion of sensors to monitor the printer as well as the process. This paper presents an open-source hardware upgrade for low-cost 3D printers to enable research on new high-temperature polymers as well as manufacturing from all currently available polymers. The hardware cost less than $1700, including the printer. Open-source firmware by Klipper and Fluidd is used for control. The printer is able to reach 500 °C nozzle, 200 °C heated bed, and 135 °C heated chamber with all electronics inside operating within the recommended temperature range. The presented design produced a CF-PEEK 3DBenchy and a spiral vase with excellent surface quality and no signs of delamination. Test specimens according to ISO527 using PA-CF performed similarly to the datasheet provided by the manufacturer for samples produced in the XY-orientation and outperformed the datasheet by 15 % in the ZX direction. Compared to specimens made on an Original Prusa i3 MK3S, the modified printer produced specimens with 22% higher strength in the YX-direction and 25% in ZX. By continuously monitoring and carefully calibrating both hardware and firmware, the presented design can perform as a research tool in material science and produce large-scale components of high-performance polymers.

Highlights

To print high-performance polymers, a stable running printer that can reach high temperatures is needed
Fused Filament Fabrication (FFF) is a process where thermoplastic filament is extruded through a heated nozzle and parts are built layer by layer
Common materials used for these machines are low-cost commodity and engineering polymers, such as acrylonitrile butadiene styrene (ABS), polylactide (PLA) and polyethylene terephthalate (PET) [4]

Summary

Introduction

To print high-performance polymers, a stable running printer that can reach high temperatures is needed. An M5x10mm bolt, a nut, and a cable crimp, mount high-temperature silicone wire (HRW) to the hole marked in Fig. 17 to ground the plate.

Results

Conclusion