My visit to Chesterfield was an exciting one today. I worked with Natalia, a PHD student who explained to me various forms of 3D Printing and their pros and cons. See the photo below for a detailed chart of the main different types. For reference, I have worked with Material Extrusion (ultimaker), powder bed fusion (titanium printer), and vat photopolymerization (the carbon printer). Natalia explained how different printers have different tendencies to create structural defects and she is researching how to address and minimize these inconsistencies. For example, material extrusion printers result in printing by layer, so the x and y axis of the structure are relatively strong, but the z-axis may be weaker since the space between layers allows structural weakness. Natalia is testing what settings would be most optimal for printers to minimize this decrease in “weld strength.”
Natalia is currently working with three different materials: PCU (Polycarbonate urethane), the flexible but fairly strong polymer I worked with Friday, PEEK (Poly ether ether ketone) an crysalline polymer, and PEKK (poly ether ketone ketone), an amorphuous polymer. The latter two materials are unique in that they require much higher temperatures than the average 200*C to melt. Normal material extrusion printers can’t attain a temperature that high on their nozzles, so a special material extrusion printer with an enclosure and extra heated build plate is required to print PEEK and PEKK, going up to 450*C. Unfortunately, this printer had some teflon stuck in the spool feeder, so we had to put the whole tube in the oven at 190*C to melt it out. Luckily, we succeeded and reinstalled the tube into the printer after a an hour or two of heating!
After explaining the different material types, Natalia gave me a more detailed tour of the lab. One interesting contraption is the extruder that creates printable materials. Normally, a spool of material of a specified diameter (1.95 or 2.85 mm) is used for material extrusion printing (see the provided image for reference). However, manufactures may not produce materials that come in spools; rather, they come in pellet form. This extruder machine converts these pellets into a usable spool of printing material by melting the material and reforming it into a thread. It’s a shame, however, that the machine is currently broken since the extrusion tip is clogged. The lab members are working on fixing it, but they have no idea what is wrong after multiple attempts to follow standard protocol. In theory, the machine is highly useful for producing spools of important materials that you can’t buy of the shelf in spool form.
Throughout the lab, there are also other components that need fixing. We looked at the Lulzbot, a material extrusion printer with a twist; it has a flexistrude tip that allows for more accurate extrusion since the motor that moves the spool is closer to the tip. On this contraption, Natalia and I worked on fixing one of the resistors that heats up the nozzle, as well as the temperature indicator on the device. Meanwhile, we printed a cylinder of PCU on a second Lulzbot; this cylinder will later be cut with the laser cutter into a dog bone for mechanical testing, similar to what I did on Friday with Will. After a failed attempt and some more troubleshooting, the print was on its way to be done! One fun fact about material extrusion printing that we took into account while printing the cylinders is: a skirt (small ring around object) is required to help with inconsistencies in the extrusion and may also provide support for the structure.
Overall, today was a fun and educational day! Natalia was very friendly and explained the project well – I hope I can learn even more from her tomorrow. Hopefully the last day will be the best one yet!
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