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YALFE - YET ANOTHER LYMAN'S FILAMENT EXTRUDER

by Cos, published

YALFE - YET ANOTHER LYMAN'S FILAMENT EXTRUDER by Cos Mar 16, 2013

Description

! PLEASE LOOK FOR YALFE V2!
http://www.thingiverse.com/thing:212894

This is my derivative from Mr Lyman's filament extruder enriched with some of Bottleworks' ideas.

UPDATE :
-REAR PHOTOS ADDED FOR ASSEMBLY GUIDANCE PURPOSES
-FRONT PHOTO REPLACED WITH CURRENT VERSION
-TEST PRINT OF EXTRUDED ABS ADDED.
PROJECT RESULTS:


EVERYTHING IS WORKING PERFECT, I FINALLY MANAGED TO EXTRUDE FILAMENT. TEST PRINTS (CHECK PHOTOS) SHOWED THAT HOME EXTRUDED ABS FILAMENT CAN BE USED FOR 3D PRINTING.

In 'instructions' section, i also explain some serious issues i confronted and how i solved them.

Recent Comments

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???? ????! ?????? ?? ???????? ?? ?? ??????
To make wood filament you need to
mix very fine wood dust and some plastic. However, sometime
in the future someone will release the secret recipe to make wood
filament..
Concerning the shredder BOM ..i need first to make the filament production working from chick to toe..
check my new YALFE V2 thingiverse.com/thing:212894

When i will be successful, then i will release the shredder part.
After all, what can you do with the shredder if you cannot make the
filament?

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Instructions

Better see Lyman filament extruder v2 http://www.thingiverse.com/thing:34653
and
bottleworks derivative http://www.thingiverse.com/thing:32667

The file contains the drawing for the Aluminium part.
I extrude 3,00mm ~ 2,8mm filament. Nozzle hole is 2,5mm.

What i added, was to put an old monitor cooling fan (something i did not use at all for 10 years now - a good friend gave it to me). It cools the hopper. I did not have to put any heat insulator as Lyman did.

Also i put a switch for the nozzle fan. Almost all the parts are from Lyman's BOM.
My preliminary extrudes showed that i have to heat ABS first, in order to dry it(80 C for 1 hour). ABS absorbs moisture and makes blobs and pops when extruded untreated.

Switches : (right to left)
-Main switch
-Emergency stop
-Motor switch
-Temp switch
-Nozzle fan switch (the little black dot upper left from temp switch)
The hopper cooler fan is always on
Rear view photos will follow

issues.

I have some issues with ABS treatment (as mentioned above). On route, next time i will try to dry some before extrusion.
UPDATE
although i heated the granules for 1 1/2 hours at 80 C, the filament quality sucks... the filament surface is rough due to pops of stinky fumes from inside the plastic.. i guess that my abs suck... i will give it a final heat for 3 hours (i have about 1/2 kilos it is a pity to through it away). New tests showed that my ABS is MORE than cr@ppy... However, nice sculptures can be created .... see thing: http://www.thingiverse.com/thing:93709
This turn of things is a good lesson for us not to underestimate raw materials.
UPDATE
The problem was not the moisture, but the cooling air from the monitor ventilator. It seems that the blown air was interfering strongly with the heater section making core temp unstable. I moved the cooler underneath the hopper. Problem solved. Hopper is cool.

While extruding, temp drops, causing the plastic to get hard again, and stop extruding... this is a major problem.. i think it is my fault because i did not wait enough (1/2 hours) as Lyman pointed out, for the PID to set itself... i will try to be more patient next time ....
problem solved, i also moved the temp sensor near the nozzle

Another major issue is the STINK of molten plastic. i have an idea of a fume suction system, i have already the active carbon and the material to enclose it. i need to find a motor, a flexible tube, and a decent design... i am open to to suggestions...
i believe that the stink comes from the moisture that is trapped inside the plastic. this causes all the quality problems (see above)
i think with the right quality with no moisture the stink problem will be eliminated or at least will be controllable.
UPDATE
The stink comes from the BOILED plastic due to temp core instability caused by the pipe cooler. Problem solved, see above.

GENERAL RULES OF THUMB FOR EXTRUDING

1 try to extrude at low temps.
2 the right plastic viscosity for extruding is that the plastic feels like 'play doh' or 'blue tack' . It must be a little bit hard. This can be controlled by adjusting core temp, extrusion velocity and nozzle cooler proximity.
3 There is not just one extrusion temp because the temp probe is not positioned at the same spot due to different extruder designs. Experimentation is required. Start at 190 C and test extrusion. if plastic comes out easily, try lower temp by 2 C.If not, raise temp by 5 C
4 If you work with plastic that is long time out of the bag, you need to dry it. Try 80C for 1~2 hours, using oven with hot AIR. the granule height layer should be low. Prefer a screen instead of a dish to help air flow through granules. I haven' tested microwave oven, but if you do, try less that a minute heating time.

Materials
The main pipe is custom made from Aluminium. (thnx to Aris)
The sprocket is a standard 30 teeth 1/2 inch, machined with a lathe to reduce weight , and make a hexagon hole for the auger bit.(thnks to Savvas)
The auger bit i used is a Milwaukee (or AEG) @16mm with hexagon end shaft
The heating element is custom made, 250W, 220V.
I used a lot the L-bracket by Azdle http://www.thingiverse.com/thing:2226

???? ????! ?????? ?? ???????? ?? ?? ??????
Check YALFE V2!

thingiverse.com/thing:212894
YALFE V2 - YET ANOTHER LYMAN'S FILAMENT EXTRUDER V2
by Cos
To make wood filament you need to mix very fine wood dust and some plastic (i think). However, sometime in the future someone will release the secret recipe to make wood filament..
Concerning the shredder BOM ..i need first to make the filament production working from chick to toe..
check my new YALFE V2 thingiverse.com/thing:212894

When i will be successful, then i will release the shredder part. After all, what can you do with the shredder if you cannot make the filament?
YALFE V2 - YET ANOTHER LYMAN'S FILAMENT EXTRUDER V2
by Cos
if they can make wood filament, will we get hemp too? please post a BOM when you work out the shredder part
Cos - in reply to SML
To make wood filament you need to
mix very fine wood dust and some plastic. However, sometime
in the future someone will release the secret recipe to make wood
filament..
Concerning the shredder BOM ..i need first to make the filament production working from chick to toe..
check my new YALFE V2 thingiverse.com/thing:212894

When i will be successful, then i will release the shredder part.
After all, what can you do with the shredder if you cannot make the
filament?
YALFE V2 - YET ANOTHER LYMAN'S FILAMENT EXTRUDER V2
by Cos
is there a way to grind/cut up or melt scrap plastic from extruding and remake filament with it. instead of just buying pellets?
Cos - in reply to n2ri
I am working on a mini shredder powered by the extruder s motor. Keep in touch. Of course if you intend to work on scrap prints you need first to clean them
so when you start making it for sale and it can re-melt used ABS into 1.75mm exact filament let me know how much I can buy one for as this will save lots of wasted plastic like the powder type 3D printers do. then only draw back with extruded over powder type is no suport needed with powder type. as size and waste will be same
Cos - in reply to n2ri
I am sorry, i do not intent to get into sales. However, there is one seller at ebay......

ebay.com/sch/adamb135/m.html?item=181154178360&;rd=1&ssPageName=WDVW&cmd=ViewItem&category=92150&ih=008&rt=nc&_trksid=p2047675.l2562

also you can search at kickstarters :

kickstarter.com/projects/833191773/filastruder-a-robust-inexpensive-filament-extruder

filabot.com/

kickstarter.com/projects/1574214560/desktop-plastic-extrusion-system-for-everyone

3ders.org/articles/20130502-3d-printing-filament-extruder-launched-on-kickstarter.html
nice setup and nice results after the first trials :)

so for us metric guys you used a 16mm auger inside a 1/2 inch pipe? did it fit well ? Is there any play associated with those two elements not matching exactly??

and can you give us any specifics on the heating element you constructed?
Cos - in reply to waste
The auger bit fits perfectly into the 1/2 Pipe.you don't need to fit Perfectly because the auger Needs to have some space to rotate. Concerning the heating element is custom made I put an order to an industrial equipment shop quoting only power Input, consumption and dimentions
Congrats on your work. Still I am stuck at making good quality filament. I think I have the same problem like you with air bubbles and motor stops extrude. Would you mind telling me your wiper motor's specification? What is its torque, power?
Mine is 7Nm, do you think it is strong enough?
Cos - in reply to scorbi
Thanks for your kind words.
If you see bubbles along with fumes accompanied with stop of extrusion but the motor is rotating, then you are certainly baking the plastic! lower the core temp by 20 or 30 C immediately!
If the motor stops moving, then you need a stronger one. Mine is a loot from a car motor wiper, these are very strong.
If you have only bubbles then you have to remove moisture from the granules. see my instructions.
what is that display and where can i buy it
display: check ebay under pid controller like this ebay.com/itm/AC-110-240V-Digital-PID-Temperature-controller-25A-SSR-K-thermocouple-Sensor-/370827585920?pt=LH_DefaultDomain_0&;hash=item56570be980 or try to find something to match mine.

where to buyQ check this ebay.com/itm/Filament-Extruder-For-3D-Printing-Lymans-RepRap-Makerbot-3D-Printer/181154178360?ssPageName=WDVW&;rd=1&ih=008&category=92150&cmd=ViewItem or you have to make one DIY
What's the best viscosity to extrude of abs filament or other plastic?? Lower or higher?
I am not a chemical engineer, nor do i work in the plastic extrusion industry, but what can you do with it if you know it? temperature controls viscosity, so you only need to know your extrusion temp. I use the extrusion temp for printing, lowering it by a factor of 10C since i want the extruded plastic a bit harder in order to keep its shape and cool faster at the exit. Of course, as i mentioned in the issues paragraph, i still did not manage to extrude quality filament due to temp variations while extruding...
Don't blame me! i could not find thinner threaded flange!!! :-)
That's where it all begun!
Fantastic! How's the filament? Printed with it yet?
Yes i did!Check the photos!
Not yet. I realised that i used a step-up voltage regulator instead of step-down. Thats why i cannot lower motor voltage. I am waiting for the right one to come from china.... The RPMs that correspond to 12 volts are too much for a good filament quality
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