I 3D-printed my self

A while ago, i got the oppertunity to 3D- scan my head with a professional scanner. The scanner picked up very tiny details, but the raw mesh output had to be cleaned and modified heavily. This is a capture of the raw scan before fixing, and making myself more beautiful.

After fixing the mesh, and adding a pedestal, i got got a printable file. Now my megalomaniac tendencies have been satisfied, and i can sleep well tonigth.

New portfolio: nordvikmanifestation.portfoliobox.net

Wooden screwdriver set

Even tho i am a big fan of mass production, the tray that my screw drivers came in was poorly moulded from crappy plastic. I decided to remake the tray in oak plywood and aluminium.

This was a good exercise in Autodesk Fusion 360 toolpath generation.

The brass screws where made from 8mm rod, and the slits where cut with a jewelers hacksaw. Then they where turned in the lathe so that they sit flush with the aluminium frame.

This is the toolpaths for the aluminium frame. it has roughing offsets, to make space for evacuating the chips from the cut.

This is where things gets complicated. The wooden tray is 3D milled. That means that the CNC machine is moving with all axises at the same time, to produce smooth edges with a round cutter.

Testing out 3D milling in Fusion 360 once more

Today i did some more testing of Fusion 360`s CAM module.

I made a sample 100 X 100 X 50 body, then made a  T-spline plane ontop of it. I then gave it some random topography to work with.

After boundary filling , the part is ready for Toolpath generation!

I intended to run the first files in foam, so i ramped up the feedrate to 3000mm/min @ 15000 RPM.

I used 10mm two flute HSS tools from GARR for this job, a ballnose for the topography, then a flat end for cutting out the part.

The results where good! At 2,5 mm stepover, the toolpaths are clearly visible.

I continued to use the same file for testing in wood. This was made using only adaptive clearing with a HSS 1FL6 from norswiss.

Rigid FDM delta printer

Altough we have a few FDM printers at Bitraf, i now see the need for having my own at my office. i started to develop a small scale delta printer last week.

The printer is constructed from a plates milled from sheet of 10mm 6082 t651 aluminium.

Movement is performed by NEMA17 steppermotors, and HIWIN linear bearing rails.

This is what i have modeled so far:

As the ultimakers, this design also equips the captured nut concept, in this case M6 nuts, as seen in this cutaway:

In this cutaway, the belt tenison system can been seen in the lower left corner. Notice the stiffening bracket in the middle of the linear rail assembly, and the milled weigth reducing pockets.

These are the main components of the printer, here laid out, ready for toolpath generation.

I decided to use this project as a testcase for Fusion 360`CAM strategies, in this case adaptive clearing.

The milling bits normaly break When peak loads is achived when running into a corner. Therefore, the feedrate must be reduced for the entirety of the toolpath when using normal CAM strategies for avoiding milling bit failure:

What adaptive clearing does, is to slowly dig the milling bit into the material, before performing a series of deep cuts at maximum depth, with optimal chipload. In this way, the tool will not experience peeks in loads, as the tool will have constand load. This reduces the runtime with a suposed 40%

I will spend the next weeks experimenting further with Fusion CAM. This is my first result with adaptive clearing:

Dust extraction for the shopbot

Today me and and Jens Dyvik assembled the new dust extractor for one of the shopbots.

The parts were previously milled out by Jens, using his CAM plugin for rhino, called barkbeetle.

Barkbetle can stream to our projector, so that we can preview files before we run them.

Seen here is the finished parts, along with the prewiew.

Polishing 3D print and metal objects

While 3D printing is great and all, it suffers from surface quality issues. My solution to this is tumbling. 

By attaching the rubberised shaft ftom a printer in the drillpress i had a tubling machine. 

The tumbler itself is made from a sewage pipe connector, with rubber bits attached on the inside to atchieve the tumling effect.