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Filament Extruder

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OSAT Filament Extruder[edit]

Project developed by User:Nick D.
Status
This OSAT has been designed but not yet tested - use at own risk.
This OSAT has been prototyped.

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Abstract[edit]

Filament is expensive. Recycled plastic is cheap. This extruder allows you to create cheap filament from ground/pelletized plastic. Important!!!! You will need metal working tools to make this properly, a lathe and mill are highly recommended but it is possible to get a way with an angle grinder and drill press. This is a very early prototype. It functions but is not ready for the mass market more work is needed.

Assembled Extruder
runing extruder
Assembled Extruder
Assembled Extruder
Assembled Extruder
Assembled Extruder


Bill of Materials[edit]

The STL file for the part and openSCAD file can be found here: File:Coupler.stl

File:Bearing block.stl


Tools needed for fabrication of the extruder[edit]

  1. Lathe
  2. Mill
  3. Drill Press
  4. Files
  5. Wrenches
  6. Allen Wrenches
  7. Screwdrivers


Skills and Knowledge Necessary to Make the OSAT[edit]

  • Machining
  • Basic circuity
  • Basic knowledge of plastic Extrusion

Technical Specifications and Assembly Instructions[edit]

  • Grind/mill 2 inch slot into 1/2 npt x 6 inch pipe so that plastic pellets can enter the feed screw.
  • Drill 1.25mm hole into center of brass cap to make nozzle.
  • Need to remove paint from ship auger bit use oxy/acetylene torch and hit with a burst of oxygen while moving along the bit. using the motor to turn the bit is very effective. Do not get bit too hot or it will warp!!
  • Machine remaining metal parts to prints provided.
  • Wrap 2 layers of Kapton tape around the barrel end closest to the nozzle. Then wrap nichrome around barrel making a 2 inch long coil without letting the individual coils touch, can be done in one layer no more than 2. Wrap coil in a second layer of Kapton to keep coil in place. total resistance should be more than 120 ohms more is okay less means you need to redo the coil or risk fire hazard.
  • Assemble similar to filastruder instructions.

Common Problems and Solutions[edit]

PLA has low melt strength and makes a small coil when extruding. Filament winder is needed. When changing filaments material is caught between two sections of pipe in floor flange necessitating removal of barrel to remove previous plastic. Crystalline plastics(PET,PE,PP,etc) can cause catastrophic failure. Extrude at own risk! Do not extrude indoors!


Cost savings[edit]

Abs is available for $3.00 a Kg compared to $20.00 for mystery ABS. PLA is available for $4.50 a Kg compared to $22.00 poor tolerance filament. Polycarbonate is available for $20.00 Kg compared to $75.00.