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Gingerbread stave church

by kempton, published

Gingerbread stave church by kempton Dec 19, 2016

Design Tools

Fusion 360

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Thing Statistics

300Views 42Downloads

Summary

Introducing the 3D printed gingerbread stave church!

YOUTUBE VIDEO - https://www.youtube.com/watch?v=m6eZp_2E8tY

This project has been driven by a single idea – to additively fabricate a gingerbread house, or stave church in this case. Gingerbread houses are usually made as flats, then cooked and finally assembled. The real challenge for me was to make a dough that hold itself upright, which normal gingerbread dough doesn't do very well. To achieve this i have been working at formulating a custom dough (which is still subject to change), as well as modifying the printer to print liquid-based materials with a heated nozzle.

The printer i have been using is a WASP 2040 delta with a modified clay extruder, which they sell as the LDM extruder (Liquid Deposition Modeling). The printer's extrusion process is two-fold – a large cylindrical tank with liquid material is pressed to the extruder with 4.5 bar pressure. Then the material is feeded through the nozzle with a mechanical screw.

In order for the dough to dry quickly, I have modified the nozzle with a heater block, which heats the dough to 85 degrees C.

Print Settings

Printer:

WASP 2040 LDM mode

Rafts:

No

Supports:

No

Resolution:

1mm layer thickness

Infill:

0 (infill in stl file)


Notes:

For this project i have been printing with a modified WASP 2040 delta printer in LDM mode. Gingerbread dough is a challenging material to print with, and for this occasion I have modified the extruder with a heater block, which provides 85degrees C to the nozzle.

dough recipe:
Syrup 210g
Sugar 170g
Butter 80g
Cinnamon 2 tbs
Cloves 1 tbs
Ginger 2 tbs
Flour (type 0) 600g
3 eggs
30g Sunflower oil
200g maizena
100ml vodka

Post-Printing

Icing the house

by hand... for now...

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As you said, you needed a special recipe for the gingerbread dough. I understand why the normal one would not work. but it's not obvious to me what would. I would appreciate if you could share the recipe.

So, i just updated the post to include the dough recipe. I have to say that the perfect dough recipe is yet to be found. I have hear rumors about glykose syrup and rye flour make a strong bond when heated, i will try this later.

Very nice, it held up quite well.

When I saw the initial picture I so wanted there to be a dual extrusion for the icing.
Something like a droop print, a flat single layer of the criss-cross to fall down on the sloped roof.
Alas, probably one hurdle too many for such a boundary pushing hardware setup.

Any detail on this secret gingerbread recipe or the mechanics of the extruder?

It would be truly awesome to have a robot doing the icing. problem though is the fact that the gingerbread needs to be baked.
I will share some blueprints for the extruder as soon as i have time. It looks a lot like the original Ultimaker hotend screwed onto the LDM extruder by WASP.

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