Figure 4 3d printing

Figure 4 - 3D Printer

Figure 4® Factory Solutions

Productive and cost-effective digital manufacturing solutions for production environments

There is a Figure 4 solution to match any production requirements:

Figure 4 enables high-speed direct digital production, a process that complements traditional production methods, providing manufacturers the accuracy, reliability, repeatability, and uptime of traditional molding, producing parts without the costs and time-consuming aspects of tooling.

Manufacturing Redefined

3D Systems Figure 4 makes 3D production a reality—with increased productivity, durability, repeatability and lower total cost of operations (TCO). Figure 4 delivers productivity enabled through speed and automation with real world repeatable, accurate parts with demonstrated Six Sigma performance in a diverse range of robust, production-grade materials.

High Speed Direct Digital Production

Figure 4 delivers ultra-fast additive manufacturing technology with systems that offer expandable capacity to meet your present and future needs. With access to a range of innovative materials, Figure 4 enables tool-less alternatives to traditional injection molding or urethane casting processes with direct digital production of precision plastic parts. Get the quality and performance of injection-molded parts with smooth surface finish and exceptional sidewall quality, without the time or cost of tooling.

Download the direct digital production white paper

Modular Platform Grows with Manufacturing Needs

Delivered in configurable units for anytime scalability, Figure 4 allows manufacturing capacity to grow alongside demand – from a standalone printer for rapid prototyping and low volume direct 3D production, to modular systems that grow as your volume grows, up to a fully-automated, fully-integrated factory solution.

The broad and expanding range of materials available for Figure 4 addresses a wide variety of applications needs, for functional prototyping, direct production of end-use parts, molding and casting, and includes rigid and durable with thermoplastic-like behaviors, rubber-like, castable, heat resistant and biocompatible capable materials.

Advance Your Workflow
Figure 4 solutions use 3D Sprint, 3D Systems’ advanced software for file preparation, editing, printing, and management from a single, intuitive interface. 3D Sprint automatically generates exceptionally efficient supports and optimization requiring far less material, which can lead to significant savings.
Maximize Your Production
3D Connect brings a new level of management in 3D production, with fleet monitoring and remote diagnostic applications. 3D Connect Service provides a secure cloud-based connection to 3D Systems service teams for proactive and preventative support to enable better service, improve uptime and deliver production assurance for your system.

3D printing with plastics offers many choices for engineering grade materials, elastomers and composites. Do you need flexibility? Strength? Bio-compatibility? More?
3D print with plastics to build almost anything - used for prototyping, manufacturing, anatomical models and more. Select a plastic material and 3D technology to deliver the characteristics you need.

Interested in purchasing a printer?

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Figure 4 Solutions

Figure 4 Production

Industry’s first customizable, fully-integrated factory solution for direct digital production

Figure 4 Modular

Scalable, semi-automated 3D manufacturing solution designed to scale with growth

Figure 4 Standalone

Ultra-fast and affordable for same day prototyping and low-volume production

Figure 4 Jewelry

Ultra-fast and affordable 3D printing solution for jewelry design and manufacturing workflows

Figure 4 Standalone - 3D Printer

Affordability

Part of 3D Systems’ scalable, fully integrated Figure 4^® technology platform, Figure 4 Standalone is an affordable and versatile solution for low volume production, and same-day prototyping for fast design iteration and verification, offering speed, quality, and accuracy with industrial-grade durability, service, and support. With a compact and easy-to-use design, Figure 4 Standalone delivers industrial-grade durability at an affordable price and low total cost of operations.

Versatility

Quick and easy material changeover allows for functional prototyping and production application diversity with the same printer. Featuring a manual material feed, it is augmented with separate post-processing units available for cleaning, drying, and curing.

Explore Materials

Customer Stories

Fast Turnaround

Achieve same-day functional prototyping and low volume production with ultra-high speeds. Figure 4 Standalone offers quality, accuracy, and Six Sigma repeatability (Cpk > 2) with industrial-grade durability, service, and support. Figure 4 Standalone was designed for ease-of-use and includes file preparation and print management with 3D Systems 3D Sprint software.

Broad Range of Materials

3D Systems’ Material Design Center has over 30 years of proven R&D experience and process development expertise. The broad and expanding range of materials available for Figure 4 Standalone addresses a wide variety of applications needs, for functional prototyping, direct production of end-use parts, molding and casting, and includes rigid and durable with thermoplastic-like behaviors, rubber-like, castable, heat resistant, and biocompatible capable materials.

Note: Not all materials are available in all countries. Please consult your local sales representative for availability.

About this printer

Applications
Benefits
Tech Specs

Applications

Replacement of traditional molding and cast urethane processes
Rapid functional prototyping and fast concept models
Investment casting patterns for jewelry
End-use durable plastic parts
Short run production of plastic articles
Jigs and fixtures
Rapid tooling -molds and master patterns
Elastomeric parts –prototypes of grommets, seals, hoses, weatherstripping, tubes, gaskets, spacers and other vibration dampening components
Medical applications requiring biocompatibility and/or thermal resistance

Benefits

Affordable initial investment
High throughput vs. competitive 3D printing technologies
Industrial-grade durability
Print and use same day
Low total cost of operations
Application flexibility
Efficient design iteration
Six Sigma quality and repeatability

Tech Specs

Non-contact membrane Figure 4 technology
Printable Build Volume (W x D x H):124.8 x 70.2 x 196 mm (4.9 x 2.8 x 7.7 in)
Industry-leading 3D Sprint software for file preparation and production
Cloud connectivity for predictive and prompt service with 3D Connect capability.
Production-grade materials
Compact printer footprint
Manual material feed
Separate, manual post-curing unit, required

The broad and expanding range of materials available for Figure 4 addresses a wide variety of applications needs, for functional prototyping, direct production of end-use parts, molding and casting. Chose from rigid and durable materials with thermoplastic-like behaviors, rubber-like, castable, heat resistant, and biocompatible capable materials.

3D printing with plastics offers many choices for engineering grade materials, elastomers and composites. Do you need flexibility? Strength? Bio-compatibility? More?
3D print with plastics to build almost anything - used for prototyping, manufacturing, anatomical models and more. Select a plastic material and 3D technology to deliver the characteristics you need.

Interested in purchasing this printer?

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Industry - None -Academic & ResearchAerospace & DefenseDentalHealthcareManufacturing & PrototypingTransportation & Motorsports

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Job Level -- Select Job Level --C-LevelPresident or VPDirectorManagerProfessional StaffConsultant or ContractorIntern or StudentHobbyist

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Area of Interest - Select -Medical Device Design and ManufacturingMedical SimulatorsAnatomical ModelsD2P SoftwareDental Manufacturing and Design Services

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Figure 4 Production

Industry’s first customizable, fully-integrated factory solution for direct digital production

Figure 4 Modular

Scalable, semi-automated 3D manufacturing solution designed to scale with growth

How to make a 3D model for printing on a 3D printer from an ordinary picture / 3D printers, machines and accessories / iXBT Live

If you want to make a 3D model from a regular drawing on a 3D printer, this instruction may help you. In a couple of steps, it is quite easy to convert any image from JPG into a three-dimensional model for printing on a 3D printer. Of course, we will talk about simple drawings, not portraits, etc. Make a logo, 3D text, a 3D diagram and print it. Well, you never know, sometimes it is necessary. So today I was puzzled by such a question. And it turns out that the answer is not so easy to find. nine0003

I'll tell you right away. This instruction is more suitable for beginners who are just mastering 3D printing and 3D modeling of people. Any specialist, of course, knows everything that I will show below. But we all started from scratch. Therefore, I hope that this information will be useful for beginners.

Owning a 3D printer, I'm slowly mastering Fusion 360. And I wanted to print a pretty nice motor club logo. Here it is frozen. But for instructions, I'll take a simpler option. So. We have an image. And we want to make a 3D model out of it for printing on a 3D printer. nine0003

Something like this:

Yes, I took the IXBT logo. The first one, found in jpg in a search engine:

I throw the file into CorelDRAW. In it, first we convert the JPG to a raster (the “Raster Images” tab, select “Convert to a Bitmap Image”), then we perform the “Quick Trace” action:

At the output, we get a file ready for export. Now select "Save As" and save our file in DXF format ( this is important ):

Then open the Autodesk Fusion 360 program. I make 3D models in this program, since it is quite easy to learn, and it is also free for non-commercial use. nine0003

In Fusion, open the previously saved file, and see this:

Well, now everything is simple. Hold down the CTRL button and select each element with the mouse. Then we press the E button and choose at what height we need to make the text in volume:

Well, that's all. The volume text is ready. It remains only to export the model to an STL file, feed it into Cura (or your 3D printing program) and print

This is what I got:

I chose a quick print, without a substrate. Before printing, I didn’t calibrate the table, so the dot before com was lost (fell off), but it’s not scary, because I printed only for example and clarity. nine0003

In the same way, you can convert not only text, but also a simple picture, logo, design element, etc. into an STL file for printing. And where it can then be applied, depends only on your imagination. The main thing is that now you have an implementation tool.

I hope this instruction was useful, and I did not in vain transfer a few grams of plastic.

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Custom 3D printer with ToolChanger

After a long operation and modification of our 3D printer, it was decided to build a new one from scratch, taking into account the shortcomings identified during operation. One of the latest improvements was the replacement of the control board from MKS SBase running Marlin (which worked with external TCM2208 drivers in the XY axes) with the duet2 WiFi clone from MKS, which I accidentally came across, which I wrote about earlier. After working with this clone for a couple of days, it became unambiguously clear that the ease of setting up and using this board is much better, and also opened up many new features that were not in the old printer. nine0003

In parallel, options for using the automatic filament changer system were considered, and in the end it was decided that the ToolChanger idea proposed by E3D was the most interesting. Especially since the control board was already on hand.

However, I did not like some of the E3D concepts incorporated into their ToolChanger printer, namely:

Double deck belt layout. It's not that she's bad, I just don't like her.
Console table. There was an experience in the first printer I made, it will never be in my printer again. nine0060
The frame concept was also not to my liking because the profiles had to be attached to the end face of the milled board. Because of this, there was no distance from the table under the printer that I needed, and above the printer there was no way to close the printer with a regular lid. And I did not have the opportunity to accurately saw off profiles of equal length at home, and this is very important.

After sitting in Solidworks for a month and a half, I sketched out a project. The project was not completed to the end, only the details that needed to be milled were made in detail. Printed parts have been modified during assembly, initial operation and printer setup. Pre-printed all the parts needed to run the new printer. nine0003

So, having looked at my old printer for the last time, I took it apart. Most of its parts will go into the new printer.

Figure 1 - Old 3D printer

Frame

The frame is based on two milled aluminum plates 5mm thick. The top plate is designed to assemble the main kinematics, accommodating Y-axis rails, XY motors, docking stations, etc. The bottom plate serves as the bottom of the frame and is solid. The lower bearings of the table drive screws, the Z-axis motor are mounted on it.

Figure 2 - Milled body and portal parts

Profiles 20x20 are fixed with screws along the perimeter of the plate. They increase the rigidity of the plate and allow using other profiles, in fact, to assemble the frame together. The profiles are fastened together with metal corner and T-shaped plates 4 mm thick. The frame turned out to be quite rigid, despite the size of the profiles. I know many will say that 20x20 profiles are not enough. Perhaps the operation will show. nine0003

Figure 3 - 3D printer frame (in the process of assembly)

From the outside, the frame is covered with 3 mm thick acrylic walls. They do not affect the rigidity of the frame, but they will protect against dust and drafts. In addition, filament spool holders are placed on the side walls. The design of the housing allows you to place coils inside the printer. The top and front walls of the printer are removable. I decided not to make doors that open in front - they turn out to be very large and will interfere when open. It's easier to just remove the panel, it is fixed on magnets. I did not remove the protective coating from the top cover. nine0003

Figure 4 – appearance of the 3D printer

Kinematics

The printer uses classic CoreXY kinematics with 10mm high criss-cross belts. Along the Y axis, movement is carried out on MGN12 rails with long carriages. A milled aluminum beam 4 mm thick is installed on the Y-axis carriages through 4mm thick aluminum spacers (see Figure 2), to which the X-axis MGN12 rail is screwed. They don't get hot during printing. As rollers, F624ZZ bearings were used, mounted on screws with an interference fit (the main body of the screw is solid, the thread is only at the end of the screw). The thread is M3, and the diameter of the screw body is 4mm. nine0003

Screws for installing bearings F624ZZ

It is possible that after prolonged use they will either be pulled out of the plate, or they will bend. Anyone who wants to repeat this - keep this in mind.

Figure 5 - Kinematics (top and bottom view)

Belt tensioners not included. The tension is carried out when the belt is installed and fixed in the X-axis carriage (in the E3D printer exactly the same). Yes, it's not very convenient. But I was not able to come up with a normal adequate tensioner design. There were several options, but I didn't like any of them. Operation shows that even without tensioners it was possible to sufficiently tension the belts in this way. nine0003
Table

The structure of the table is a frame made of 20x20 profiles, on which a 4 mm thick aluminum plate is rigidly fixed. Further, another aluminum plate 4 mm thick is fixed to this plate through screws with springs. A silicone heater 300x200, 220V, 600W is glued from the bottom of the top plate. Between the plates, a layer of insulation with a thickness of about 20 mm. Glass 300x200 mm 4 mm thick is installed on the top plate. The actual print area of the printer is approximately 300x200x200mm. nine0003

Figure 6 - Silicone heater 220V, 600W

The table frame is moved on two MGN12 rails by means of three lead screws connected to the motor by a circular belt. The rails are fixed on the front profiles 40x20 mm. Two screws are located near the rails, and another one is opposite on the other side of the table frame. The use of such a drive eliminates failures in the calibration of the table, as, for example, in versions driven by two or more separate motors (two motors were used in the old printer, and the calibration of the table was constantly lost). In fact, you only need to set the table once in a horizontal plane relative to the XY plane and do not touch it again. nine0003

Figure 7 - Design and appearance of the table

Figure 8 - Table drive The carriage body is made of milled aluminium. Here, good precision in the manufacture of aluminum parts is important so that the SG change mechanism works clearly and without jamming. nine0003

Figure 9 - Milled parts of the X-axis carriage

In the front and rear wall of the carriage, sleeves of a plain bearing are installed, in which the SG blocking shaft with a pin at the end moves in the radial and axial directions. The movement is carried out with the help of a servo drive and a gear reduction gear (the gear on the servo shaft has 20 teeth, and on the lock shaft 40 teeth, module 0.5). To block the steam generator, it is necessary to turn the shaft with the pin by 90 degrees. Accordingly, you need to choose a servo that can rotate 180 degrees. When the shaft engages with the SG, it also moves in the axial direction (due to the design of the receiving part of the SG). To adjust the pressing force of the PG to the carriage, a standard spring is used, which is used to adjust the level of the 3D printer table. To limit the stroke of the shaft, an adjusting washer with a set screw is installed on it.

Figure 10 - Design and appearance of the X-axis carriage

Ideally, of course, to design and manufacture your own shaft, but I did not have access to the tool to do this. Therefore, as a shaft, I used a spare part from a radio-controlled helicopter. This shaft has the necessary threads and holes (honestly peeped in one of the projects).

Figure 11 – SG blocking shaft

The counterpart of the blocking mechanism is located in the SG itself. The pin on the shaft engages with this part when the shaft is turned and, thanks to the spiral grooves in it, attracts the PG to the carriage. nine0003
The SG is centered relative to the carriage by three points and is made by analogy with the E3D proposal. On the aluminum base of the PG, 3 metal balls with a diameter of 6 mm are installed, and metal pins with a diameter of 5 mm and a length of 15 mm are fixed in the front plate of the carriage. When the carriage shaft is rotated and the PG is pulled to it, the balls fall into the gaps between the pins and thus the PG is self-centered at three points. Practice shows that this method of centering the PG is quite accurate, printing with different tools when changing one to another ensures the exact location of the nozzles of the print head relative to each other (naturally, nozzle offsets must first be calibrated and entered into the firmware). nine0003
The design feature of the carriage is the location of the Z-axis limit switch on it (except for the X-axis limit switch). The Z-axis limit switch, in addition to its direct function of the limit switch, also performs the role of a table calibration sensor. Since the PG is easily disconnected, the limit switch can easily reach the table and take the necessary values to build a height map, which can then be used to calibrate the table or to operate the automatic table uneven compensation system. As practice has shown, the design of the table turned out to be very successful, its calibration does not go astray. Therefore, even there was no need to use automatic compensation. It is enough to calibrate the table once and then just print. The advantage of such a system is the ability, if necessary, to install various types of hot ends (E3D, Volcano or Super Volcano) without changing the design of the table calibration sensor (which cannot be done, for example, when using BLTouch). Actually, the sensor itself is no longer needed separately, which simplifies the design of the X-axis carriage and the electrical part. nine0003
Design of interchangeable steam generators and docking station

The printer uses Bowden type extruders. Bontech BMG Gear Extruder clones are used as a feed mechanism, which are connected to the hot end of the corresponding PG by means of a Bowden tube.

A Chinese clone of the E3D V6 hotend is used as a hotend in replacement PGs. Now the printer has 4 PGs installed - three with a nozzle diameter of 0.4mm and one with a nozzle diameter of 0.2mm. The design of interchangeable PG is the same. The basis is an aluminum milled part (on which the mating part of the locking mechanism and balls of the self-centering mechanism are fixed) and a printed part (on which the hot end, fans for blowing the hot end and parts, as well as the air duct for blowing the part are fixed). The printed part has two holes with a diameter of 6 mm for installing the PG on the docking station when it is not in use. nine0003

Figure 12 - Milled parts of the print head

Figure 13 - Appearance of the printhead assembly

The docking station is designed for two PGs. For this, shafts with a diameter of 6 mm and a length of 30 mm are installed in it (two shafts for each steam generator). When changing the steam generator, the carriage with the installed steam generator drives up to the required station, installs the steam generator on the shafts, unlocks the steam generator blocking mechanism and drives off to a safe distance. PG remains on the docking station. The choice of the desired PG occurs in the reverse order. nine0003

Figure 14 - Printheads on docking stations

Electronics

The power supply is a 24V 350W unit. The table is powered by 220V directly through the solid state relay SSR-40 DA. An MKS PWC V2.0 block is also installed for power management. In addition, a step-down converter is provided to power the servo.

Printer controlled by MKS Duet2 WiFi clone and original Duex5. I do not use the display because of its absolute uselessness for this system. nine0003
All electronics are located at the rear of the printer. This arrangement is the most appropriate, it provides quick and complete access to the electronics at any time. This is very important due to the large number of wires connected to the electronics during the setup process.

Figure 15 - Appearance of the printer electronics compartment

For convenient connection of the moving parts of the printer (carriage, PG) with the control board, intermediate switching printed circuit boards were developed for each element - for PG, carriage, docking station). The carriage and PG are connected to the respective boards using a wiring harness and connectors (which are used in computers for power circuits), and the boards are in turn connected by wires to Duet2 WiFi and Duex5. This solution simplifies work with the electrical part and allows you to quickly remove the SG for maintenance or replacement. nine0003

Figure 16 - Breakout boards of the X-axis carriage, printhead and docking station.

A very handy addition to any 3D printer is good illumination of the print area. For these purposes, 4 LED lamps were installed in the upper part of the printer from 4 sides. They turn on with a separate button. Due to their shape, these lamps illuminate the printed area well, while not shining into the eyes and not dazzling.

Figure 17 - LED lamp

Conclusion

Here's a short summary of the printer I've built. It took about 4 months to develop and create a printer. It could have been faster. The printer is now fully configured and working. It has been profiled for Ultimaker Cura for ease of use when printing in multiple colors.

Active operation of the printer during the last 3 months shows that the printer has been successful in principle. There are a few things that could be improved, but overall the usability and print quality are satisfactory. nine0003
The project, probably, does not make sense to spread it. It is not worked out to the end, I adjusted many details just in place. There are finished projects with all the details to repeat, and even assembly and setup guides on YouTube. The same E3D posted all the sources to the network.

Also, if someone wants to repeat, first of all ask yourself the question - why do I need such a printer? For me, it was mostly just a matter of wondering if I could design and make such a printer and still work well. nine0003
I will answer questions.

Good luck!

P.S. A couple of examples of two-color printing. I wanted to try it as soon as possible, the printer had not yet been completely rebuilt and I had not yet made a profile for Cura, so blotches of colors are visible.

Useful Links

Since the printer was designed with ToolChanger, the useful links will refer to it.

FaceBook group with a lot of useful information on the design of printers with ToolChanger, mechanisms for switching and changing printheads, etc.
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