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Metal Matters
New Zealand
Приєднався 9 лис 2020
Metal 3D printing has long been a technology reserved for the commercial sector. Come with me as we the explore the possibilities additive metal manufacturing at home for a fraction of the cost.
Forum: www.metalmatters.co
Support me at: www.buymeacoffee.com/metalmatters
Forum: www.metalmatters.co
Support me at: www.buymeacoffee.com/metalmatters
DED Metal 3D Printer - Round 2
Looks like we're starting over..
Development of a DIY metal 3D printer, printing 316 stainless steel. This project aims to establish a cost effective opensource metal 3d printing platform. Subscribe for future developments & announcements.
Forum: www.metalmatters.co
BMAC: www.buymeacoffee.com/metalmatters
Laser Safety Goggles:
www.edmundoptics.com/p/mi1-lasershield-safety-goggles/41391/
Artwork/Music:
HOME - Moire Fringes
soundcloud.com/home-2001
Vivacity - Phello
Papers referenced:
"Measurement of actual powder layer height and packing density in a single layer in selective laser melting"
www.sciencedirect.com/science/article/pii/S2214860418306444
"Hot-Wire Laser-Directed Energy Deposition: Process Characteristics and Benefits of Resistive Pre-Heating of the Feedstock Wire "
www.mdpi.com/2075-4701/11/4/634/htm
Development of a DIY metal 3D printer, printing 316 stainless steel. This project aims to establish a cost effective opensource metal 3d printing platform. Subscribe for future developments & announcements.
Forum: www.metalmatters.co
BMAC: www.buymeacoffee.com/metalmatters
Laser Safety Goggles:
www.edmundoptics.com/p/mi1-lasershield-safety-goggles/41391/
Artwork/Music:
HOME - Moire Fringes
soundcloud.com/home-2001
Vivacity - Phello
Papers referenced:
"Measurement of actual powder layer height and packing density in a single layer in selective laser melting"
www.sciencedirect.com/science/article/pii/S2214860418306444
"Hot-Wire Laser-Directed Energy Deposition: Process Characteristics and Benefits of Resistive Pre-Heating of the Feedstock Wire "
www.mdpi.com/2075-4701/11/4/634/htm
Переглядів: 59 781
Відео
The End Of Metal Tracks - DIY Metal 3D Printing
Переглядів 189 тис.2 роки тому
Development of a DIY metal 3D printer, printing 316 stainless steel. This project aims to establish a cost effective opensource metal 3d printing platform. Subscribe for future developments & announcements. Forum: www.metalmatters.co BMAC: www.buymeacoffee.com/metalmatters Artwork/Music: HOME - Puzzle soundcloud.com/home-2001 Papers referenced: "Effects of sulfur concentration and Marangoni con...
SLM Metal 3D Printer - Update | Metal Matters
Переглядів 16 тис.2 роки тому
Development of a DIY metal 3D printer, printing 316 stainless steel. This project aims to establish a cost effective opensource metal 3d printing platform. Subscribe for future developments & announcements. Forum: www.metalmatters.co BMAC: www.buymeacoffee.com/metalmatters Videos referenced: TheBackyardScientist - "200 Watt car mounted laser!" ua-cam.com/video/WAI7Lu4UFi4/v-deo.html metal 3D he...
Experimenting with wire based metal 3D printing | Metal Matters
Переглядів 35 тис.2 роки тому
Development of a DIY metal 3D printer, printing 316 stainless steel. This project aims to establish a cost effective opensource metal 3d printing platform. Subscribe for future developments & announcements. Forum: www.metalmatters.co BMAC: www.buymeacoffee.com/metalmatters Papers referenced: "Additive manufacturing using fine wire-based laser metal deposition": sci-hub.se/downloads/2020-07-26/3...
Rounding off the previous progress update | Metal Matters
Переглядів 7 тис.3 роки тому
Short update. It's been quite a while since I've been able to put down any metal, limited as it is. I'm aiming to have a video out in the next couple of weeks but there are still a couple of loose ends to take care of before tackling anything more substantial. I'll discuss those in the next video.
DIY Metal 3D Printer - Progress | Metal Matters
Переглядів 58 тис.3 роки тому
Hello everyone. Long time no update. Things have been progressing steadily with the printer but I have been busy with life outside of UA-cam hence the lack of videos. I've decided to break this next update down into two parts as there is a lot of content to cover and we are well overdue for an update. With that said, I will be transitioning to full time work on this project in next couple of we...
Metal 3D Printing - An Update | Metal Matters
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Development of an i3 based metal 3D printing platform, printing 316 stainless steel. This project aims to establish a cost effective opensource metal 3d printing platform. Subscribe for future developments & announcements. CAD files pending development. Total build cost estimated to be around $1500 USD. Forum: www.metalmatters.co Laser Profiler Software: www.opticsforhire.com/laserprofilemeasur...
DIY 3D Metal Printing is becoming a reality | Metal Matters
Переглядів 39 тис.3 роки тому
Preliminary testing of an i3 based 3D metal printing platform, printing 316 stainless steel. This project aims to establish a cost effective opensource metal 3d printing platform. Subscribe for future developments & announcements. Forum to be released within the coming weeks. CAD files pending development. Total build cost estimated to be around $1500 USD.
Steps towards cost effective metal 3D printing in the home | Metal Matters
Переглядів 115 тис.3 роки тому
Preliminary testing of an i3 based 3D metal printing platform, printing 316 stainless steel. This project aims to establish a cost effective opensource metal 3d printing platform. Subscribe for future developments & announcements. Forum and CAD files to be released within the coming weeks. Total build cost estimated to be around $1500 USD. Music: soundcloud.com/rinse-cycle/hit-squad-killers
Metal Matters SLM X1 3D Metal Printer
Переглядів 9 тис.3 роки тому
Metal Matters SLM X1 3D Metal Printer
How much does it cost to build this device
All in, from safety glasses to the gas bottle, maybe $1000?
How's it been going?
Pretty good. Benchy is done. Video in the works. Couple of weeks?
@@metalmatters Heck yeah!
What are you running on the FPGA to control the galvo? I saw you were using OPAL on the teensy, are you using custom HDL or is there some IP core available somewhere? Could you also share what laser module / roughly how much it costs? Great Project!
Just using the FPGA as a differential line buffer. I have a video coming out within the next few weeks that will cover the laser.
Do you have a bevel cut on the bottom of the blade recoater? From what I have found, the bevel is used to compact the powder which plays a considerable role in final part density.
Steve, would you happen to be building one of these? Yes, you are right about that; it's one of the factors that contributes to overall part density. No, I'm using a simple blade at the moment.
@@metalmatters Not yet. For now, I'm just an annoying guy on the internet who is fascinated by the tech. I fully intend to build one if you end up releasing plans.
Apt timing; I happen to be dealing with this exact issue at the moment.
This guy only prints nylon but it is an SLS maybe you can adapt it to do metal!
I think your link was automatically removed. Are you referring to SLS4All? It's a nice build, but the price tag is a little discouraging.
Hey recently stumbled across your channel. I am fascinated. I do have a few questions. Based off your experience and time spent along with the evolving nature of sls printers trying to move more to retail people, would you suggest any printers you see out and available?
What materials are you aiming to print with?
have you seen the printer that uses electro plating to effectively print metal parts?
As per the second to last comment, yeah. I assume that is what you're referencing.
Oh this is getting good. it's getting so close to just being like, perfectly usable
I’m building the same thing but here in Brazil. I’d love to be able to exchange some info with you. I got a 60w mopa, which one are you using ?
I'm using a side pumped YAG laser. Chuck me an email if you'd like to chat.
Good to see it mostly reliably does 3d now. Great work! Do you have a milestone in mind for your next full video?
Shooting for a benchy, may settle for less. Really depends on how in depth things become.
I was exploring a bit the sls capabilities lately as I might be interested on buying a machine for plastic if afordable, but I noticed one thing, the powder is heated at 10 degrees Celsius bellow the melting point on polymers powder. I do wonder if many problems wouldn't just dissappear even on metal printing machines just by heating the powder, it eliminates moisture that powder atracts and the results are more consistent. I think what you need now is a water free environment, as much as you can do.
There are a few systems in the commercial space which preheat their chambers, sometimes to over 500C. I think keeping the build chamber at 1300C+ might pose a few too many problems to be worthwhile, though. It's necessary for nylon etc to prevent curling, but obviously the melting point is much lower.
I'd love to see someone that wants to sponsor you and some co-workers on the project. Wish you all the best, I'll keep watching this project.
Appreciate that
those cubes are shaping up nicely... would you be willing to try printing a little metal on ceramic surfaces? I could send you some plates.
Yeah, no worries. You know how to get in contact with me 😉
Always good to see you working on this project. Probably my favorite on UA-cam!
Thanks!
in the past I built a 5axis 3d printer with a mig welder, (waam, wire arc additive manufacturing) I have posted some videos of the printing process maybe they might be helpful to you
Awesome work man! keep it up :)
Thanks!
I can’t remember the entire series that you have done, did you try the “metal spray” plus laser instead of the metal spray oxy?
I tried wire DED, a relative of laser based spray deposition, but gave up on it eventually. I really need to make a video on that. Spraying metal powder is probably not something an amateur should attempt 😬
@@metalmatters Ok. Thanks. I remember the wire attempts you made. I think you were pulsing it to try and get measured droplets. Have you used the oxy spray units? I found them easy to use but covered a large area. I am very impressed with your test samples in this video. The only thought (not well thought through) was to melt the powder mid air before the solid can absorb the heat) We have all used a small soldering iron on big wires and used thermal inertia to get the bond.
@@brucebaxter6923 I have seen the oxy units for rebuilding profiles, though haven't played around with them. Did you find the gas consumption reasonable? IIRC, the powder based DED machines operate at 45 - 60 psi to overcome the surface tension of the weld pool. Not all of the media is utilized either. Thanks! Although these were all failures there's is something to be learned. The print produced during this run is much stronger and tidier compared to anything shown here.
@@metalmatters This one is most definitely neater and tidier. The height you have got with keeping dimensions is impressive. The powder is very gas consumptive, the same as an oxy welding flame. My initial thoughts were that as the powder is sucked into the centre of the flame and has to pass through the flame to get out and is heated in the process, If it was a focused laser, only the powder that was on a trajectory to where the laser is focussed will absorb the heat and melt. The rest of the powder will simply fall or blow away. I was thinking to avoid the melt pool as its shape and size are difficult to control especially as you add cold filler. As for the pressures, I’m sorry I can’t remember.
@@metalmatters It’s not applicable to what you are doing, but if you thought of an old tv tube with focus and beam guidance, this is a giant version. The other version I know of is for refining uranium isotopes and might get you flagged if you researched too far into it. ua-cam.com/video/VuMdyStDmPI/v-deo.htmlsi=BIVTKPj7gGqgTOZk
Good to see you still around.
Looked into Electrochemical Additive Manufacturing (ECAM)?
Briefly. It's an interesting concept. I think it would be difficult to achieve good results without developing a high density matrix for the process. I notice that Fabric8labs mainly showcase copper parts too.
@@metalmatters I agree, a matrix like what they have seems like the key. I don't know how much effort it would take to create something like it in the open-source community but I'd love to see it.
How goes the progress?
Pretty good. I haven't been working on things for the last week or two due to life getting in the way. I did manage to get this far, however: ibb.co/XpZV6vR
@@metalmatters That looks really good. Printed metal just has the best looking surface finish.
@@steves.5868 Thanks. It's been bead blasted in that photo, just so you know. I was in the process of figuring out the correct parameters to achieve the best surface finish, but unfortunately the logic needs some reworking due problems with EMI, and it seems the laser wasn't operating at its full capacity. It'll get there..
@@metalmattersDid you get the EMI problems worked out?
@@steves.5868 EMI problems are pretty much resolved, as much as they will be for this proof of concept. Nearly all of the logic now lives on the microcontroller. The printer has been doing everything within its capacity to stop me from working on the process itself, hence no update. I've had to rebuild a significant portion of the powder bed after it split apart late last week, amongst other things. I've been stuck in the pit lane unfortunately.
the thick spots at the start and end of metal tracks can be controlled by "skywriting" laser scan strategy in which laser start/stop emitting only when it achieves certain acceleration. However, the work you have done is still amazing and applicable, and truly speaking impossible for 1 man team.
Would doing every 5th layer or so at a thicker layer height help with the recoater collision? Does the laser pattern used have much effect on the collision frequency?
Allowing for a thicker coat to be applied? It will probably have the opposite effect. Yes, the raster pattern does affect the processed layer height. At the moment it is pretty much guaranteed to collide, but it is manageable.
Dear sir, Im sorry but I dont know your name, I following your portal from several years ago, because I'm engineer I find some of your issues in any cases that you have. I give you some advise in below texts to help you and other guys. Please try to use standard electronics board same Mach3 cnc board I use that and it works perfectly and simple. Calculate termal extension in any parts that have contact with laser beam. The powder bed ned to redesign because of termal expansion and heat reformation. You need to fix the powder bed with fixture technique dont let that to rotate or re placing. You need to remove air aound the poweder wen its busy with sintering, you know that oxidation dident let the new melted layer to joint on previous layer you can use clused chamber with argon gas or co2 gas, dont forget that you doing Sintering or welding and not cutting. You need to cooling the actuator and other plastics bodys as well, dont forget to cool down the lens or lenses frames. Finaly when you use the powder tacke care that poweder stof have 0,00004 mm as max. sizes please let the machine working more on each layer , you need to use the section layers closeer to each others and dont put blaser beam for long time on one point. I want to visit your website but its out of access, I dont know whay. With my best wishes for you and your familie. Farbod.
Hi Farbod. Thanks for your insights. Many of the above issues have been addressed. The system is semi operational now. The website was taken down due to inactivity. Hopefully I will have together a video for you all soon.
Great footage as always! I need to get one of those cameras for rotoforge!
How do you handle the powder safely?
I only work with stainless steel, which is considered one of the lesser metal powders in terms of danger ( 'non-reactive' / low bioavailability). With that said, I still wear gloves, a respirator, and try to only expose certain items of clothing to that environment. Static and metal fume are things I am working on.
Glad to see you back.
The stuff you do is so awesome! Good luck and keep us updated!
Will do. Hopefully, the updates are a bit more frequent now that everything is together.
Well done. Been watching this evolve. Random thought? Does the powder pusher spread it at a higher x than it scrapes it back? Would that help clearance issues?
Unfortunately, no. It needs to be kept under the layer height (60um). Otherwise, it will compound until it inevitably becomes a problem.
@@metalmatters thanks. My mistake, I went off track thinking like spreading cement or gravel etc where you lay a thick layer and scrape it back off to the correct height.
Incredible to see you continuing with this. Genuinely one of the most exciting laser-based projects I've ever seen
Thanks!
Woah super cool. What kind of laser is that?
Nd:YAG
Ok cool, I think I found the module you’re using. Does it include the right mirrors and collimating optics or is that what you have externally setup?
Mini-SLS, nice.
awesome job! where did you find the camera?
Aliexpress. It's just a 48MP PCB inspection camera.
For a wiper, look at screen printers. They use a very durable polyurethane wiper. Readily available. Also it looks like you don't have an enclosed cabinet, you need to do that and remove all the oxygen, replace it with a heavier gas. Perhaps argon.... I was a welder and I know we use a trace of helium in there when tig welding. You cannot have oxygen present. Haven't watched it all, but how do you weld metals together in that atmosphere? That doesn't make any sense. Unless you're trying to make Slag.
Thanks for the insight. The black plastic container is sealed and purged with argon.
Reminds me my mtech project, thin wire is never a good option
I agree. I'm interested to know why you think this though?
@@metalmatters I used MIG power source for 250 um wire. Even at very low voltage, the moment wire touches the substrate, it will get red hot and the integrity of the wire will be lost.
@@kk3074 Ah, I guess the circumstances are a little different then. I would expect there would be some level of threshold power required to gain enough heat to melt the parent material. 250um doesn't afford you a lot.
Keep it mate, that's brilliant!
What gears did you use to feed the wire? I can’t find any that feeds 0.25mm wire.
I used a small drill chuck as the main drive roller and a bearing as an idler. I had to use a pair of opposing syringes to guide the wire as there obviously isn't any groove for the wire to follow.
Is it just pressure that pulls the wire through the wheels?
Yep. You want a decent amount (sorry, I don't have any figures).
My other question is how do you remove the oil off the stainless steel wire?
Hoping you don't completely drop the slm project. It would be cool to see the pros and cons of slm vs ded.
I would love to progress to a metal printer, but considering all the big boys have gone down the route of SLS of metal powders I think for the hobby level of printing, doing it in resin first to create a mould and then using that mould to create your metal part is the cheaper option that produces higher quality metal parts than you would get from any setup like this.
"Remnents of the ded system" Is wire printer kill?
Yes. Kaput. It improved, but there were some underlying problems I could not surpass.
@@metalmatters Unfortunate. The powder printer are much more cool anyway.
No one I'm aware of in the industry has cracked dimensionally-perfect additively-manufactured metal parts. CNC giants like DMG Mori or Hermle "solved" the problem by sticking additive metal systems inside 5-axis CNC mill-turn machining centers. Folks need to accept that additive manufacturing is much like traditional casting, it'll get you close to the desired shape, but tight tolerances will always require machining.
@metalmatters. Your website is down, would like to make contact to share information based on my hands on experience. Cheers
Didn't see this until now. You can contact me via the about page, my email is listed there.
Love it
8:39 Use a kitchen-blender, used for making smoothies and crushed ice. It makes powder so fine, that you have to keep its lid closed for a while when ready, or a cloud of fine dust will fill the room.
I love what you’re doing, is there anyway that anyone else could help support you or contribute to the project? Do you have a discord?
Not currently. I am almost at a point where we will find out if this approach is viable. I'll re-evaluate following that. Appreciate the gesture though.
What type of laser system did you move too?
You do know that what you said makes no sense to like 99% of all people? Glad to be part of that 1%😎
Cool man, make some more updates. Good progress, keep pishing ❤❤❤
More frequent video updates would be really cool. And really cool work btw.
Noted. Thanks!