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Chocolate Extruder

by ttsalo, published

Chocolate Extruder by ttsalo Feb 23, 2012

Description

This is a heated chocolate extruder based on the Moineau pump (progressive cavity pump) principle.

It can be used to print objects from chocolate.

Recent Comments

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Some people are afraid of ABS as parts of it are toxic. However, once extruded and cooled I think it's pretty safe.
thesoftlanding.com/is-acrylonitrile-butadiene-styrene-abs-plastic-toxic/
The first prototypes I made were PLA and deformed when washing leftover chocolate from them... I recently printed one from polycarbonate, which looks good and should be a good material for this, and plan on testing it when I have time.
great thing, I will give it a try in PET (so afraid by PLA and with a heat source near by)

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Instructions

Print the parts. There are two driveshafts, for motors with 20 and 24 mm shafts, others can be produced from the .scad file. Also, there are two versions of the main body, one with "fixed2" in the name (the original) and the other, marked "fixed4", where a couple of minor manifold issues have been fixed with netfabb. These should otherwise be 100% identical and the netfabb-fixed one should slice and print more reliably, but I have not actually printed that one.

I recommend 0.20mm layer height. 0.25 might work too, but more than that probably won't. Note: PLA is sort of food-safe, but ABS most likely isn't. Don't use ABS except when printing for purely decorative purposes.

Drill a hole in the nozzle, 1.2 mm and 1.6 mm are good starting points. Cut a gasket for the nozzle flange, I used bicycle inner tube. Attach nozzle with M3 nuts and M3x10 bolts.

From the other end, push the rotor all the way into the stator cavity, then fit the driveshaft and attach a NEMA17 stepper motor with the motor coupler piece fitted to the end of the motor shaft (requires flats on two sides), making sure that the coupling teeth fit together.

The extruder should now be ready to be fitted to the printer - it bolts directly into the latest Prusa X carriage with the 40mm circular hole.

The extruder also needs warm air - otherwise trying to get repeatable results or results at all is hopeless. The pipe opposite the funnel can be used to fit an air hose (I used a washing machine water outlet hose). The air circulates inside the heat shroud around the pump and inlet block and exits around the funnel. A shoe dryer supplies the warm air in my setup. The temperature should be just a little below 30C.

The object to be printed can be sliced into GCODE pretty much the same as when printing with plastic, but the layer height should be larger to accommodate the larger nozzle, and the filament diameter has to be set much higher. In my setup, with E_STEPS_PER_MM set in the firmware to 1800 and with a 1.2 nozzle, I used 18mm as the filament diameter to print the Flying Spaghetti Monster seen in the pictures. (Layer height was 0.7mm). The effective filament diameter also depends on the nozzle size, since smaller nozzles cause more backflow in the pump (because with plastic parts, it won't seal properly). Also, set the infill density to 100% - chocolate really doesn't handle overhangs...

Then it's time to melt some chocolate (I wrote a bit about it here: http://reprap.org/wiki/Chocolate_Extrusion but the main point is: don't exceed 33.8C), pour it into the extruder's supply funnel and see what happens.

Some people are afraid of ABS as parts of it are toxic. However, once extruded and cooled I think it's pretty safe.
thesoftlanding.com/is-acrylonitrile-butadiene-styrene-abs-plastic-toxic/
great thing, I will give it a try in PET (so afraid by PLA and with a heat source near by)
The first prototypes I made were PLA and deformed when washing leftover chocolate from them... I recently printed one from polycarbonate, which looks good and should be a good material for this, and plan on testing it when I have time.
The stepper shaft, for example, has 90degree overhangs. Will this be printed correctly without a support material?
Yes, it prints fine without support, but some of the bridges are a bit challenging, expecially inside the main part where it narrows down.
try ice under the build platform :)
Haha Funny. I bet I can come up with a design for an icecube holder that hangs underneath. Genius!
What did you use to keep air flowing at 30C? I don't have an air compressor...
I used a hot air blower, made for drying shoes and gloves.
Hi Tomi. Here you can find my chocolate cooler if of any interest: thingiverse.com/thing:19354

It outputs around -15 degree Celsius of cool air stream. Workshop air compressor needed.
Chocolate Cooler
by Ioan
Hi Tomi. Wonderfull work! I want to ask you how quickly the chocolate is hardening? Did you considered using a cooler to help the layers hardening more quickly? Look at this design: thing:8114. It is a vortex tube, works with compressed air at 5 bar. On one side it will output warm air, higher than room temp. and on the other side will output COOL AIR at may be -20 deg. C. Also you can find more reliable designs on the internet. Such vortex tubes are used in industry for spot cooling which is exactly what we want!
ttsalo - in reply to Ioan
I have been testing with no extra cooling and it hardens quite slowly. To build more interesting objects, it will need some sort of external cooling. I have been thinking of everything from peltier elements mounted under the build plate to blowing cooled air. This is an open area of research if anyone wants to have a go...
Ioan - in reply to ttsalo
Here is an example of how a small company was helped to quickly cool down chocolate molds: blog.exair.com/2011/11/01/refrigerated-air-from-compressed-air/

I think this is the way to go. It is small, it can spot cooli the thin chocolate filament very quickly. The Exair prodicts are a little bit expensive however there are some DIY projects around.

One more thing: may be the same compressed air/vortex cooler can be used both to keep the chocolate warm and cool the printed part due the unique feature of this device.
Chocolate needs to stay below 33, but if you wound the temperature up to 70 or 80, it could print polymorph!, just add a hopper arangement above the material feed and we're free of the problems of filament tolerance and quality, just pour in a bag of granuals and go.
That stuff sounds interesting, but it looks like it won't flow on it's own? This extruder requires the material to flow down the supply funnel without external help. The pump itself can pump pretty much anything but the supply side works with just gravity here.
That's a great idea! Did you consider using water to heat the chocolate? You could connect up two small pipes and then use an aquarium heater+pump to pump a properly controlled temperature of water around the extruder.
I did consider that, but since the chocolate comes in preheated and only needs to be held a couple of degrees above room temperature, the power of water heating isn't really needed. Air is simpler and tiny leaks don't matter (it may not be easy to make all the thin walls totally watertight).
what an excellent idea! my wife is also thrilled! :)

slic3r 0.7 sais that the model is not manifold, could you fix that please?

Thanks!
I ran the main extruder STL through netfabb and sure enough, that found a couple of degenerate faces. That fixed version can now be found under the name "choco_stepper_main_fixed4.stl". I'm leaving the original version with fixed2 in the name just in case.
I checked it out with the Slic3r 0.7.0 and yep, it did complain about not being manifold. I then exported a new STL with the newest OpenSCAD version but it still complains. I checked the output, newest OpenSDAD and newest Slic3r, layer by layer, and it looks totally correct. So I think it's safe to print even with the complaints. The newest STL should show up with "fixed3" in the filename.
&
gt;Don't use ABS except when printing for purely decorative purposes.

I was under the impression it was completely food-safe, and is the same stuff Lego bricks are made out of.

ABS does give off some fumes while decomposing, however.
ABS contains styrene which is made from benzene, which causes cancer and other nasty things. I would avoid using it with foodstuffs unless I had the data sheet for the specific brand I'm using and that had a food-safe certification for it. PLA is a better bet, it has an FDA approval as food safe.
I wouldn't bet that anything but "natural" PLA would be considered food safe, without seeing a certification for it. While the PLA itself might be food safe, the additives and colorants used in it may not be.

I'd suggest giving it a coating of food safe urethane, except that the moving parts are likely to just end up wearing the coating off anyway.
Wish I could like this one a second time... Nicely done! 8-)
I had to stare at the Thingiview for awhile before I understood: you actually direct the hot air through a jacket around the entire mechanism to keep it evenly warm. Hat's off, that's a spectacular design. As someone who has tempered chocolate by hand to make truffles, I understand how important keeping an accurate temperature is. What this really needs is a PID temp control like the other extruders.
Yeah, I actually thought that chocolate was an easy material to work with before I tried this... proper temperature control is a must. I haven't fitted an actual sensor inside this (yet) and I'm not sure what would be a good location.
Ideally if you have temperature control on your hot air supply you should put the sensor as close to the nozzle as you can get it so you know what temperature you are putting down. The closer you put it to the chocolate / air mixing chamber the less accurate it will be. Just a thought, but have you thought about using an induction coil? If it works at the low temps it might be less cumbersome and easier to monitor then using heated air.
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