Monday, September 29, 2014

WOOF Come One Come All 2014 - 2015 3D Printing Club Introductory Meeting


 Salutations 3D Printing Enthusiasts,

It was our pleasure to meet all of you this week. In order to further introduce you to our club we’d like to invite you to attend our introductory “Come One Come All” meeting on Monday, Sept. 29th, at 5:00PM. The meeting will be held in the Mechanical Engineering Building in room MEB 246. There will be several opportunities presented at the meeting:

First, we’ll introduce you to the Printrbot Simple. This is the printer kit we’ll be offering this quarter. It’s a nice little printer and assembles very quickly. Everyone that orders one through the club will get special work times set aside to put the printer kits together with the aid of WOOF officers.

Second, we’ll be introducing our projects for this year. If you are interested in design, mechanics of printers, large format printing, printing in composite materials, writing code, electronics, or control systems, we’ll introduce you to the projects we have planned. If you have an idea of your own, you could also start your own project and we’ll help you form a team to take it on. Once the meeting is over, you can group up and speak with project leads about anything you are interested in.

Third, the money. Membership dues are $20 for a year, renewing in September. So if you think you may want to join us, or you are renewing your membership, bring $20 cash to the meeting. If you won’t have a twenty on Monday, it’s no big deal, you can contact us to pay at another time. If you are interested in a Printrbot, we’ll be taking payment for those kits at a later date.

Fourth, we’ll have a quick optional “How to Get into 3D Printing” lecture 15 minutes before the meeting at 4:45. This will be a first of a series of optional mini-lectures to help you jump into the technology.

Thank you for your time and have a great weekend!

Washington Open Object Fabricators

P.S. Any questions can be directed to woof3d@uw.edu

Friday, September 26, 2014

WOOF Successful Outreach at UW Dawg Daze



Jeff and Kim at the WOOF booth

Wednesday and Thursday September 24th and 25th WOOF participated in the University of Washington’s annual First Year Programs Dawg Daze (http://www.uwdawgdaze.com/)  held in Red Square. In wind and rain, WOOF used the opportunity to introduce interested students to some of WOOF’s projects, encourage them to sign up for the mailing list and to attend the upcoming “Come One Come All” meeting. On display were a collection of 3D objects printed in a variety of materials such as poly lactic acid (PLA), a carbon fiber composite PLA and recycled HDPE. Running off of a 12 volt Fire Engine battery and a power inverter was this year's printer kit - the Printrbot - offered for sale to anyone interested in building their own 3D printer. Enthusiasm for the club was high with 290 students expressing interest. WOOF welcomes new members from all backgrounds and levels of experience. Anyone is welcome to drop by the WOOF room - Room G045 on the ground floor (almost the basement) of the UW's Mechanical Engineering Building (MEB G045).
Printrbot, filament, and objects printed and cast in different materials: PLA, Carbon Fiber Composite PLA and Brass

Saturday, August 30, 2014

WOOF Members Attend 3D Printer World Expo in Bellevue



Friday August 22, 2014 

WOOF members had the opportunity to attend the 3D Printer World Expo held at the Bellevue Regency Hyatt in Bellevue WA. 3D Printer World Expo Bellevue, WA Aug 22-23, 2014

The Expo was well attended and the 3d Printer research, design and manufacturing communities were well represented. University of Washington Mechanical Engineering Professor Mark Ganter, one of WOOF’s faculty advisers, gave a presentation on 3D printing materials sustainability.  After Friday’s closure, Professor Ganter accompanied a group of WOOF’s officers to the Cheesecake Factory in Bellevue.

Photo Credit: Mark Stamnes

When asked about the experience, WOOF Officer Mark Hanson stated “For me, it was exciting to see the innovations people have made in the consumer market. I loved comparing the various ways people are doing more with less as we continue to perfect these machines.” 

This experience helped bring WOOF onto a broader playing field and allowed WOOF to connect and catch up with current 3D Printer innovators like Lulzbot, Makerbot, Matter Hackers, Flashforge and Leapfrog.

HDPE Print Bed Adhesion Solution



3D printing using recycled HDPE (shredded gallon milk jug flakes) comes with many challenges, one of them being print bed adhesion. HDPE has become infamous to WOOF for its uncontrolled warping and shrinking, which causes prints to peel off of the print bed. To mitigate this, WOOF Officer Brandon Bowman began developing a process to create an HDPE print surface. 

The initial idea was to heat gun HDPE flakes onto steel plates (18” X 18” X 1/8"). This evolved into baking using a standard baking oven. Bowman initially baked HDPE flake onto a steel plate then applied force on top of the flake using another surface, his body weight and his feet.

Photo Credit: Brandon BowmanPhoto Credit: Brandon Bowman

This process produced inconsistent and non-optimal results. Size limits of the baking oven, the need to put plastic in an oven, and the need to apply spray on Teflon coating encouraged designing a different solution.
  
Over time the flake baking process evolved into a recipe reasonably perfected by WOOF’s Director of Operations Dana Henshaw. The following recipe utilizing a Wabash Hot Press has produced promising results:

Stack 4 plates prepared in the below manner with a 5th steel plate by itself as a barrier on top into a hot press.
To prepare each steel plate requires:

1 - 24” X 24” Steel Plate (1/8” thick)
Photo Credit: Dana Henshaw

3 - Pints of Recycled HDPE Milk Jug Flakes (cleaned and shredded) spread on the steel plate leaving an approximately 1" border.
Photo Credit: Dana Henshaw

1 – 24” X 24” Sheet of Porous Teflon Coated Fabric

Photo Credit: Dana Henshaw
1 – 24” X 24” Sheet of Breather Material

Photo Credit: Dana Henshaw


Finally top the sheet off with: 
1 – 24” X 24” Sheet of Non-Porous Teflon Coated Fabric (Not Pictured)


Then using a Hot Press:

Photo Credit: Mark Stamnes

Apply and maintain 400lbs of force
Increase temperature to 375 °F over 30 minutes
Hold at 375 °F for 40 minutes
Cool for 10 – 20 minutes
Remove the 400lbs of force and separate hot press platens
Then carefully remove the hot plates

After the plates are cooled, they are attached to the build surface and then used for printing.

Photo Credit: Mark Stamnes

This is an attempt to print a cylinder that was to be used as a potential floatation device.

Photo Credit: Mark Stamnes

Photo Credit: Mark Stamnes


This turned out to be a great learning experience. Here are a few things that were tried but did not work: 

Failure of first hot press: Used only non-porous Teflon coated fabric. It made sheets that were too smooth, and the first layer of printed HDPE wouldn't adhere well enough.

Failure of second hot press: holding pressure for 20 minutes with the breather material was not long enough for temperature to penetrate deep enough into the stack to allow full adhesion of HDPE flake onto each plate. The HDPE on the middle plates stayed as flakes.
 
In all, developing this process has allowed the WOOF team to achieve successful prints of the sections a multi-sectioned Kayak.