LYMAN FILAMENT EXTRUDER V3 - Amazon Web Services€¦ · me many of the features included in Version 3, which includes water cooler, micro processor, nozzle ori-fice size, puller

LYMANFILAMENTEXTRUDERV3

CREDITS:

Jay Morgan – American Plastic Profiles http://www.americanplasticprofiles.com/

Johnny Russell – Ultimachine https://ultimachine.com

Jeff Moe – Aleph Objects, Inc

http://www.lulzbot.com/

Charlene Angle– Dimension Engineering, LLC http://www.dimensionengineering.com/

Zach Kaplan—Inventables, Inc

https://www.inventables.com/

FABRICATION&OPERATIONMANUALDESKTOP FILAMENT EXTRUDING SYSTEM – 9/2/13

Lyman Filament Extruder V3 Video:

http://www.youtube.com/watch?v=p_E7crY9wfg

The Lyman Filament Extruder V3 is an open source product licensed under

http://creativecommons.org/licenses/by-sa/3.0/

There will be some errors and omissions, as there always are. First watch the video on YouTube, read and study the entire Manual as well as all the comments on Thingiverse of two prior versions, then you may contact me at the email below. Changes, additions and corrections are welcome as I consider this still as a work in progress. Contact: [email protected]

See the video on YouTube

SABERTOOTH & KANGAROO This micro processor is mounted on the control panel for easy access to the Kangaroo motor pots, wherein the puller motor can be adjusted to sync with the extruder motor. The motors have to be tuned to the processor so it is important to follow the instructions. carefully.

WATER COOLING TANK I cut the Plexiglas tank parts on a laser en-graver cutter, (complements of Inventables). A work in progress is a tank with 1/4” Plexiglas, wherein a resizing die with be included. See part drawings. Water temperature never ex-ceeded 35 degrees Celsius.

PULLER ROLLER ASSEMBLY 3D printed these parts, combined motor mount with roller housing for easy setup. The idler roller cradle has a 3/8” hole in the top where a wood dowel stud is inserted to hold the bottom of the spring in place. The top 3/8” bolt holds the top of the spring in place. The bearing and motor holes have to be dressed for a snug fit.

LEVEL WIND REEL W/COUNTER. The handle is removed and the spool is filled with masking tape to a diameter that gave a correct count on the counter. The strip of sandpaper is used to help feed the filament through under the spool. In watching the video you will see why cooling tank and the reel are not attached to the base.

SPOOL WINDUP ASSEMBLY This is the same design as my original Spool Winder as seen on YouTube. It can accommodate different size spools. As there are many size spools you will need different size spool collars. The stl file I have included is only one size, so design your own.

FILAMENT EXTRUDER This turned out to be a work of art. Eliminated a whole bunch of hardware. One simple hopper and motor mount. It is printed with extruded ABS Lyman filament. Note the auger is surrounded with pellets when filled. The Extruder is not attached to the base so it can be tipped to empty the pellets. I tried several flexible couplers and this is the one I used. On the first assembly, alignment was good. The coupler is drilled and taped for two set screws to engage the flat part of the shafts, as the tightening screws that comes with the coupler won’t hold under torque. The Plexi-glas hopper allows for visual reference of the pellet level and is removable. The lead weight maintains a steady pressure on the pellets. It takes two filling of the hopper to extrude enough filament to fill a 1kg spool.

TEMP READINGS Nozzle— 175C Flange— 65C Insulator— 36C Hopper Base—34C Water— 35C

EXPLAMATION OF CREDITS Jay Morgan is the Vice President of American Plastic Profiles. After he read articles about my wining the Desktop Factory Competition, he gave me a call. He told me he was going to build an extruder similar to mine for extruding Silicone. Over the last six months he has become a very good friend and has given me many of the features included in Version 3, which includes water cooler, micro processor, nozzle ori-fice size, puller roller and others. Johnny Russell is with Ultimachine, a company that I have purchased many parts from for 3D printing. He was so gracious in supplying me with motors and giving me other help. Unfortunately the motors are not used in the Extruder. Jeff Moe is the owner of Aleph Objects, another company I purchase 3D printer parts from. He has helped my greatly in my early days of 3D printing and never hesitated to answer a question or to help me solve a problem. I believe he will soon be offering Extruders for sale. Charlene Angle is with Dimension Engineering Company which furnished the micro processor for the extruder. She has spent hours, days and weeks helping me to accomplish making the system work. This processor procedure was new to me, but she never gave up when I was ready to and she kept prodding me on. Watch her video on there website. Zach Kaplan is the owner of Inventables who developed the Desktop Factory Competition, he is listed last but not least. As I am living on retirement income at 84, winning the competition helped make this invention possible. It took two submissions to get his attention and then he spent considerable time in the approval of the invention. One morning early in March I got a phone call from Zach, that my extruder passed all the test and is the winner. It was and is a very good feeling. Zach came to Seattle and my wife and I met him and had dinner, he is an amassing young man. As this is probably the last invention I will accomplish, I am pleased to share it with the World. HELLO WORLD

TOOLS USED

1. Table Saw

2. Band Saw

3. 3D Printer

4. Laser Engraver Cutter *

5. Drill Press

6. Grinder

7. CNC Router *

8. Welder *

9. Cut Off Saw *

10. Sander *

11. Thread Tap Dies

12. Soldering Iron

13. Hot Melt Gun

14. Dremel

15. Metal Lathe *

16. Lead Electric Melter *

17. Misc Hand Tools

* All these tools may not be needed as some functions can be done by hand or subbed out and engraving is optional.

NOTES: Please note that in the Bill of Materials (BOM) the costs shown in many cases are estimated. Many parts have to be purchased in quantities greater than is needed. Also different products can be used. Listed is a BOM for just the Extruder alone with the required electronics. It requires a lot less time and materials from prior versions. The motor will not need and encoder. I have cross referenced the drawings and part numbers for ease of finding, however don’t be sur-prised if errors are found. I am not yet satisfied with the filament diameter tolerances. The diameter of 1.75mm filament is greater than I would like, however I have extruded now over 8 spools of filament and have been using it in my Printer. I have not yet extruded 3mm filament, but will try shortly. My first two versions of the Lyman Filament Extruder extruded at about 8” of filament per minute at 212 degree Celsius. I learned later that I was using injection molding filament, not extrusion grade. Also they had a less powerful motor. Using the correct grade filament Version 3 is extruding at 30” per minute 1.75mm filament at 175 C. The counter showed about 1100 ft per 1 kg spool, 7+ hours. I have visions of getting 48” per min-ute. The diameter is varying from 1.65 to 1.85mm ,which however seems to print just fine. The theory of the system is to have the puller rollers pulling the filament from the extruder with mo-tors sync rate adjusted to obtain the correct diameter. Thus, the extruder nozzle orifice is 1.5 times larger than the desired diameter. Four variables control the filament diameter: 1. Nozzle orifice diameter (adjusted with a drill bit) 2. Nozzle temperature (adjusted with PID). 3. Motors sync (adjusted with Kangaroo pots). 4. Extruding speed (adjusted with manual pot). As this is still a work in progress, I plan on adjusting all four variables and installing a resizing die at the inlet (left side) of the water tank to improve the tolerances. Hope you enjoy the manual. Good luck, Hugh Lyman

Part # Dwg # DESCRIPTION QTY UNIT Unit Est Price

Total Est Price

SUPPLIER PART # or ID where I got it

SUPPLIERNOTES: These suppliers are only suggestions and better pricing

may be found elsewhere

71 A11 Aluminum Flat Bar 1/8"x 1/2" 1 FT $0.43 $0.43 OnLine Metals

45 A07 Auger Bit 5/8"X 18 1 EA $26.38 $26.38 2878A15 McMaster Carr

12 A07 Band Heater 1" 1 EA $24.00 $24.00 G2156542 Zoro Tools Needs a little enlarging by prying open at little

88 A12 Battery 24V NMH 1 EA $10.08 $10.08 ebatteryoutlet eBay I made with rechargeable 1.2V NMH batteries

66 A10 Bearing Ball Flanged 1/4" 2 EA $5.00 $10.00 6383K213 McMaster Carr

21 A07 & A08 Bearing Thrust 3/8" 1 EA $2.47 $2.47 6655K15 McMaster Carr

34 A08 Bearings Ball 3/8" 4 EA $4.50 $18.00 6383K16 McMaster Carr

14 A07 Black Iron Nipple 1/2" NPT x 3.5" 1 EA $1.28 $1.28 44615K554 McMaster Carr

13 A07 Black Pipe Coupling 1/2"NPT 1 EA $1.00 $1.00 46685K264 McMaster Carr OD Diameter should be 1.06" for 1"heat band

36 A08 Bolt 3/8"x 1" 1 EA $0.50 $0.50 True Value Hardware On hand

11 A07 Brass Plug 1/2" NPT 1 EA $3.69 $3.69 50785K337 McMaster Carr

46 A09 Brass Plug 142" NPT 1 EA $2.00 $2.00 Fastenal Work in Progress

26 A07 Bushing Brass Flanged 3/8" 1 EA $0.70 $0.70 6338K414 McMaster Carr

24 A07 & A08 Coupler Flexible 6.35m x 10mm 2 EA $8.00 $16.00 giorgio11185 eBay

10 A04 Funnel 45 FT $0.04 $1.80 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

84 A12 Fuse Holder & Fuse 5A 1 EA $2.00 $2.00 071‐510 Parts Express Optional

23 A07 & A08 Gear Motor w/Encoder 2 EA $79.00 $158.00 TD‐044‐013 SuperDroll Robotics Included Pull‐up Board & Hookup Kit

3 A06 Hardboard 1/4 2 SF $1.00 $2.00 Home Depot Ön hand

19 A07 Hopper & Motor Base 33 FT $0.04 $1.32 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

18 A07 Insulation Bd Rigid 1/2 1 SF $12.80 $12.80 9353K31 McMaster Carr More than you will need

79 A12 Kangaroo add‐on 1 EA $24.00 $24.00 Kangaroo x2 Dimension Engineering Check with Supplier for additional parts needed

90 A12 Knob for Pots 2 EA $0.04 $0.08 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

69 A10 Latex Tube 3/4" & 1/2" dia 1 LOT $5.00 $5.00 808 & 1608 Latex‐Tubing.com Purchased 12" of each

81 A12 LED Green Small 2 EA $1.00 $2.00 Parts Express Optional ‐ goes on 110V Circuits ‐ On hand

76 A12 LED Red Small 2 EA $1.00 $2.00 Parts Express Optional ‐ go on 24V Circuits

72 A11 Level Wind Fishing Reel 1 EA $50.00 $50.00 eBay Optional ‐ I used an old one with a counter I had on hand

1 A05 MDF BOARD 1/2" 3.5 SF $1.00 $3.50 Home Depot Use what ever you have, plywood etc.

4 A06 MDF BOARD 1/2" 2 SF $1.00 $2.00 Home Depot On hand All can be cut from I piece 24"x 48"

5 A06 MDF BOARD 1/2" 1 SF $1.00 $1.00 Home Depot On hand

50 A10 MDF BOARD 1/2" 0.6 SF $1.00 $0.60 Home Depot On hand




8 A04 MDF BOARD 3/4", 1/4 1 SF $1.50 $1.50 Home Depot Use what ever you have, plywood etc.

54 A10 Mini Gear Motor 1 EA $10.00 $10.00 hjb0805 eBay This 12V so need a voltage regulator

BOM ‐ LYMAN FILAMENT EXTRUDER V3 (sorted by Description)

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Total Est Price





62 A10 Motor Arm for Winder Motor 25 FT $0.04 $1.00 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

65 A10 Nut Hex 1/4" NyLok 1 EA $0.15 $0.15 97135A210 McMaster Carr You will buy 25 ea. or get them at hardware store

15 A07 Nut Hex M4 NyLok 4 EA $0.11 $0.44 40147 Fastenal


64 A10 Nuts Hex 1/4" 4 EA $0.10 $0.40 True Value Hardware On hand

80 A12 PID 1 EA $27.00 $27.00 mambate eBay

68 A10 Plastic Spool 1 EA $0.00 $0.00 Everybody On Hand

9 A04 Plexiglas 1/8" 0.2 SF $5.05 $1.01 24161‐01 Inventables.com

35 A08 Plexiglas 1/8" 1 SF $5.05 $5.05 24161‐01 Inventables.com


75 A12 Potentiometers 5K 2 EA $16.00 $32.00 882‐MW22B‐3‐5K Mouser

86 A12 Power Supply 24V 1 EA $24.00 $24.00 hi‐etech eBay

47 A09 PTFE 1/4" DIA 1 EA $2.00 $2.00 McMaster Carr Work in Progress

42 A09 Pump Aquarium 110V 1 EA $6.84 $6.84 cll_petsupplies eBay

82 A12 Resistors 1M ohms 2 EA $1.00 $2.00 Pats Express Optional ‐ goes on 110V Circuits ‐ On hand

77 A12 Resistors 320 ohms 2 EA $0.50 $1.00 Parts Express Optional ‐ goes on 110V Circuits ‐ On hand

39 A08 Rod Steel 3/8"x 3.5" 1 EA $1.00 $1.00 8920K135 McMaster Carr


33 A08 Roller & Motor Base 203 FT $0.04 $8.12 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

38 A08 Roller Idle Bracket 59 FT $0.04 $2.36 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

2 A05 Rubber Bumper Feet 4 EA $0.50 $2.00 True Value Hardware

78 A12 Sabertooth 2X12 1 EA $80.00 $80.00 Sabertooth 2X12 Dimension Engineering Check with Supplier for additional parts needed

87 A12 Sabertooth Standoff 15 FT $0.04 $0.60 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

44 A09 Scrap Block 1 EA $0.01 $0.01 HML (me) On Hand

56 A10 Screw Cap M3 x 10mm 2 EA $0.12 $0.23 Fastenal

25 A07 & A08 Screw Cap M3 x 15mm 8 EA $0.20 $1.60 Fastenal



40 A08 Screw PHSM #4 x 1/2" 2 EA $0.05 $0.10 True Value Hardware On hand

6 A06 & A10 Screw PHSM #6 x 1" 10 EA $0.05 $0.50 True Value Hardware On hand


7 A06 & A11 Screw PHSM #6 x 3/4" 8 EA $0.05 $0.40 True Value Hardware On hand

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Total Est Price





57 A10 Screw PHSM #8 x 1" 1 EA $0.05 $0.05 True Value Hardware On hand


85 A12 Solid State Relay 1 EA $6.00 $6.00 eBay

58 A10 Spool Collar 17 FT $0.04 $0.68 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface


37 A08 Spring 1/2"x 1" 1 EA $1.50 $1.50 True Value Hardware Compression type

67 A10 Spring 1/4"x 2" 1 EA $1.50 $1.50 True Value Hardware Extension type

17 A07 Steel Flat (Flange) 1/4" 1 EA $20.00 $20.00 OnLine Metals On hand

83 A12 Switch Master Off On 1 EA $2.29 $2.29 sseariver2009 eBay Optional

74 A12 Switch SPST 5 EA $0.95 $4.75 12216 SW MAJPA

30 A07 Thermocouple Type K 1 EA $1.24 $1.24 tinxi‐clothes eBay

63 A10 Threaded Rod 1/4" 1 FT $1.00 $1.00 Home Depot You may have to buy 3 feet

43 A09 Tubing Flexible 1/4" 1 FT $1.88 $1.88 5792K35 McMaster Carr You will buy 5 ft @ $1.88 per ft

32 A08 Urethane Drive Rollers 2 EA $30.00 $60.00 2475K61 McMaster Carr

91 A12 Variable Voltage Control 1 EA $5.00 $5.00 e‐worldseller eBay

27 A07 Washer Flat 3/8" 1 EA $0.10 $0.10 True Value Hardware

22 A07 & A08 Washer Flat M3 8 EA $0.02 $0.16 40352 Fastenal

55 A10 Washer Flat M3 2 EA $0.02 $0.04 40352 Fastenal



29 A07 Washers Phenolic 1/8" 1 EA $14.50 $14.50 8710K537 McMaster Carr 6x6 sheet

48 not used

49 not used

73 not used

Contingencies, TTT, Findings 1 LOT $80.00 $80.00 estimated Items not listed or missed, connectors, zip ties, and etc.

SUB TOTAL COST $806.54

ESTIMATED FRT IN @ 10% $80.65

TOTAL COST $887.19

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BOM ‐ LYMAN FILAMENT EXTRUDER V3 (sorted by Part #)

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48 not used

49 not used
























Page 8


Total Est Price





73 not used






















TOTAL COST $888.14

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Total Est Price








































BOM ‐ LYMAN FILAMENT EXTRUDER V3 (sorted by Supplier)

Page 10


Total Est Price










































Page 11


Total Est Price




















48 not used

49 not used

73 not used




TOTAL COST $885.65

Page 12


Total Est Price
















13 A07 Bearing Thrust 3/8" 1 EA $2.47 $2.47 6655K15 McMaster Carr


15 A07 Gear Motor 1 EA $60.00 $60.00 TD‐044‐013 SuperDroll Robotics

16 A07 Coupler Flexible 6.35m x 10mm 1 EA $8.00 $8.00 giorgio11185 eBay















TOTAL COST $253.54

BOM ‐ LYMAN FILAMENT EXTRUDER V3 ( Extruder only no wood parts)

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Documents

LYMAN FILAMENT EXTRUDER V3 - Amazon Web Services€¦ · me many of the features included in Version 3, which includes water cooler, micro processor, nozzle ori-fice size, puller