![]() ![]() They noted that attempting to print PEI with the IR heating lamps off lead to serious print issues such as warping and delamination, though this was to be expected. Ultimately, the NASA report concluded that the modifications to the LulzBot TAZ 4 were a complete success. Objects printed in Ultem 1010 on NASA’s modified LulzBot TAZ 4. The popular E3D-v6 hotend costs less than $100 USD and was found to be capable of reaching these temperatures, though the team did need to replace its thermistor with a higher-rated model and make some adjustments to the printer’s Marlin firmware to allow it to reach temperatures that under normal circumstances would trigger a thermal shutdown. Somewhat surprisingly, the team had little trouble upgrading the TAZ 4 with a hotend and nozzle that could extrude plastics at up to 400 ☌. So in classic RepRap tradition, the team printed the third and final set of parts on the modified printer itself in a form of PEI known commercially as Ultem. The parts were reprinted in PC, but even this material wasn’t resilient enough for permanent use. Printed in ABS, these parts would have quickly failed inside the heated chamber meant to support PEEK. Like other desktop 3D printers, the TAZ 4 also utilized a number of printed parts in its construction. The stepper motors would overheat as well, but rather than trying to move them, the team at Langley Research Center opted to design cooling jackets to fit over each motor through which pressurized air could be circulated. Naturally the machine’s exposed electronics would overheat in such an environment, so they had to be relocated to the outside of the box. The first step was building an insulated enclosure that could fit around the TAZ 4, and installing an array of 35 watt infrared heating lamps inside of it. LulzBot TAZ 4 modified for high temperature printing. For a consumer 3D printer to successfully produce parts in PEI and PEEK, it would need to be extensively modified which is exactly what NASA did with a LulzBot TAZ 4 back in 2016. The printer itself, especially of the type and quality that we’ve become accustomed to at the desktop level, wouldn’t survive in such an environment. ![]() Put simply, a machine that supports these so-called engineering plastics needs to be an amalgamation of a traditional 3D printer and an oven. While it’s hard to say if we’ll see the same race to the bottom for high temperature 3D printers, the first steps towards democratizing the technology are already being made. Machines that were once the sole domain of exceptionally well funded R&D labs now sit on the workbenches of hackers and makers all over the world. Of course there was a time, not quite so long ago, where the same could have been said of 3D printers in general. The purchase price for a commercial printer with these capabilities is in the tens of thousands even on the low end, with some models priced well into the six figure range. These plastics must be extruded at temperatures approaching 400 ☌, and a sealed build chamber kept at >100 ☌ for the duration of the print is an absolute necessity. Parts made from these materials are especially desirable for aerospace applications, as they can replace metal components while being substantially lighter. Industrial 3D printers like the Apium P220 start at $30,000.īut high-end industrial 3D printers can use even stronger plastics such as polyetherimide (PEI) or members of the polyaryletherketone family (PAEK, PEEK, PEKK). That puts them on the upper end of what the hobbyist community is generally capable of working with. Not only are the extrusion temperatures of these materials greater than 250 ☌, but an enclosed print chamber is generally recommended for best results. But this is where things start to get tricky. If you need greater durability or higher heat tolerance than PETG offers, you could move on to something like acrylonitrile butadiene styrene (ABS), polycarbonate (PC), or nylon. This material isn’t much more difficult to work with than PLA, but is more durable, can handle higher temperatures, and in general is better suited for mechanical parts. The next step up is usually polyethylene terephthalate glycol (PETG). It’s a fine plastic for prototyping and light duty projects, but it won’t take long for many users to outgrow its capabilities. The downside is that objects printed in PLA tend to be somewhat brittle and have a low heat tolerance. ![]() PLA can be extruded at temperatures as low as 180 ☌, and it’s possible to get good results even without a heated bed. That’s because it’s not only the cheapest material available, but also the easiest to work with. Despite the impressive variety of thermoplastics that can be printed on consumer-level desktop 3D printers, the most commonly used filament is polylactic acid (PLA). ![]()
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