Pla pellets for 3d printing

PLA Pellets – Where to Buy and How They Are Used

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Filaments are the weapon of choice for most people who are into FDM-based 3D printing. They are convenient, easy to handle, and very easy to buy, especially considering how 3D printing suddenly became popular in the last couple of years.

However, filaments aren’t the only form in which 3D printing thermoplastics are available. Although not quite as common, these thermoplastics are still sold nowadays as pellets. In this article, we will be turning our focus on the PLA version of these pellets. How are pellets used in 3D printing and is it a good idea to get your own?

Why is PLA sold in pellets?

Selling or using any plastic in pellets really isn’t uncommon in the plastics manufacturing world. In fact, it is the base form that plastics typically take once they are produced from their constituent raw materials. For reference, plastics are typically made from a polymerization process that converts monomers (commonly petroleum-based) into a fluid slurry. This slurry then solidifies as it cools and is extruded into very small and regular sized pellets.

Plastic manufacturers prefer producing pellets simply because they are much easier to handle and pack more densely. This cuts down on the expenses related to storage and transportation, as more product can be shipped at smaller volumes.

Pellets are also a very versatile form of plastics, especially if they are used to manufacture a wide range of plastic products. The filaments used in 3D printing are simply a product of these plastic pellets getting re-melted and re-extruded into another shape. Plastic pellets can also be used to create products from hard-shell containers to very thin films.

Nowadays, PLA sold in pellet form is no longer as common, mostly because filaments are so much more convenient for 3D printing. However, there is still a market out there for PLA in pellet form, especially for those who manufacture a large number of 3D printed products regularly.

Which 3D printers can print with PLA pellets?

Pellet-based 3D printers are so rare nowadays that they always make a huge deal when a similar product is introduced. What this unfortunately implies is that they will almost certainly be more expensive than the usual desktop-scale FDM 3D printers that have become very popular.

If you’re interested in 3D printing directly from PLA pellets, the bad news is that buying one right now isn’t as straightforward as searching for it on Amazon. Over the last couple of years, crowdfunding campaigns have been run to raise money for the development of pellet-based 3D printers and to gauge interest in the product.

Out of all the efforts to develop pellet-based 3D printers, the Gigabot X by re:3D is probably the one that has received the most media mileage. Back in 2018, a Kickstarter campaign was able to raise $55,000 of funding for the Gigabot X, which was described as a large-scale direct pellet extrusion 3D printer. The company intended for the crowdfunded amount to add to their earnings from global pitch competitions, which amount to more than $225,000.

According to an update by the team in August 2018, the prototype of the Gigabot X had already been manufactured and was undergoing testing. Although the team still wanted to do a few tweaks, the tests confirmed that the concept indeed works and could be a viable alternative to 3D printing with thermoplastics. Right now, the Gigabot X is available to buy from the re:3D website and costs $16,950.

There are also a few other brands involved in this trend, including the Pam Series P and Pam Series M printers from French brand Pollen. This is another intriguing concept that uses pellet-based raw materials but there’s an added twist here – the Pam Series M printer uses metal pellets. Even the design of the Pollen 3D printers is interesting because they use a delta-style system and a print bed that moves, which allows the pellet-loaded extruder/hot end system to remain stationary.

Pollen sells an array of different thermoplastics in pellet form including PLA, ABS, HIPS, PP, PE, and even composite materials like Woodfill with PLA. They also have metal feedstock pellets for the Pam Series M printers.

Yet another interesting concept from Italy-based Direct3D. Instead of an entire 3D printer specially designed to work with pellets, Direct3D sells technology to modify popular 3D printers so that they can accept pellet-based feedstocks. Their modification takes the form of a single-piece attachment to the print head which contains a nozzle, extrusion system, and a hopper to feed the pellets.

According to Direct3D, their pellet extruder has already been tested with several 3D printers from Creality and Prusa. It can work with most of the standard 3D printing materials including PLA, ABS, TPU, TPE, PP, and PE. Obviously, you’ll need a high level of technical and DIY skills to get this modification to work with a standard FDM 3D printer.

For both Pollen and Direct3D, the prices of the respective pellet-based 3D printing technology are only available upon request. This is a practice that is commonly seen only in high-end and expensive products.

Make your own filament with PLA pellets

An alternative way to use PLA pellets is to make your own filament with it, rather than print with it directly. This mimics how filament manufacturers use PLA pellets. By doing it yourself, you get more control over the quality and appearance of the product and save on material costs over time.

The most popular way to do this is to use the Filabot Extruder, a product initially marketed as a way to recycle scrap 3D prints. It works by melting small pieces of plastic which are then pushed by an extrusion screw through a nozzle. The Filabot Extruded can be augmented with Airpath cooler and spooler add-ons to streamline the operations and improve the spool quality.

Although initially intended to make recycled filaments, the Filabot Extruder also works perfectly well for creating your own filament using pelletized raw materials. This can even be a method for making customized filaments with your own combination of additives and colors.

Pros and cons of using PLA pellets for 3D printing

While there are certainly several compelling reasons for developing pellet-based 3D printers, there’s still a huge mountain to climb before this technology becomes adopted widely by both industrial and recreational users.

PROS

Cheaper materials

As we’ve mentioned, plastic filaments are a product of reprocessing plastic pellets. By gaining the ability to work with pellets, the cost of 3D printing materials can be reduced by a huge margin. Based on the price of PLA pellets and filaments that are available today, filaments can cost up to 4 to 5 times more expensive.

Customization opportunities

If you have the equipment to make your own filaments from pellets, then you can also create filaments based exactly on what you need. This will make producing colored filament a lot like mixing paint, in that slightly different ratios can result in different colors. The technology isn’t quite mature enough for a good number of these customization options to be available, but we are thrilled with the possibilities.

Increased throughput

Most manufacturers that develop pellet-driven 3D printers have deliberately designed them to have faster throughputs than filament-based 3D printers. This is easy because pellets melt faster on account of their much larger surface area, and the screw delivery system can be made to rotate as quickly as necessary.

More ideal for large-scale 3D printing

The benefits of pellet-based 3D printing when it comes to reduced operation costs, faster throughput, and better customization are benefits that will only be realized after a long time. If you only use your 3D printer to create one or two prototypes every month or so, then printing with pellets may not be worth it. However, 3D printers that continuously operate as an element of a manufacturing process may benefit much more quickly with this technology.

CONS

Will require special hardware

By far the biggest hurdle to the more widespread use of pellets for 3D printing is the lack of hardware options. As one would expect, this lack of options also makes these special pellet-driven 3D printers very expensive.

The Gigabot X costs nearly $17,000. This price tag is likely indicative of how much this technology is going for nowadays. In an age when you can buy desktop filament-based 3D printers for less than $500, even moderately sized companies might not even consider spending the huge capital for a pellet-based 3D printer.

If you prefer going the route of making your own filament from pellets, then the Filabot Extruder will still set you back around $10,000 even without the cooling and spooling accessories.

PLA pellets are hard to find

3D printing has become so popular that you can probably buy PLA filaments in any color imaginable. You can find them in most hobby shops and art shops and looking for them online hardly takes any time. PLA pellets, on the other hand, are only sold by a few select brands. It’s not exceptionally difficult to look for them, but you’ll have to live with the fact that there aren’t a lot of options.

Consistency is problematic

Consistency is one of the strongest suits of 3D printing using a filament. A plastic filament has a virtually constant diameter and density throughout, ensuring that the same amount of material flows into the printer’s extruder and nozzle at all times. This helps filament-based 3D printers create highly refined details and worry-free print quality.

Printing with pellets makes consistency a little more challenging. No matter how well packed pellets, there will always be random pockets of empty air that will inevitably go into the extrusion screws. This means that a fully consistent flow of material into the melt chamber is virtually impossible. For this reason, pellet-based 3D printers are usually intended for large-format projects where refined details are less important.

Where to buy PLA pellets

The peculiar thing about PLA pellets is that you just can’t find them on Amazon or other online retailers. Instead, you’ll have to buy them straight from the brands that manufacture them. This is probably another indicator of how little demand there is for 3D printing pellets.

1. Filabot LX175 PLA

Unsurprisingly, the brand that manufactures the equipment for DIY filaments also sells PLA pellets. Filabot sells these pellets at a minimum order of 5 kilograms for a little less than $10 per kilogram. They also sell PLA color additives in various colors.

2. 3DXTech PLA Pellets

3DXTech sells a wide array of 3D printing pellets including PLA, ABS, HIPS, PVA, and PETG. Again, these are meant to be used to create your own filament in machines like the Filabot Extruder. If you want to add colors to your filaments, then 3DXTech also sells a fully customizable 3-color pack.

3. Pollen PLA Pellets

The Pollen brand has been very prolific in developing and promoting pellet-based 3D printing, so it’s only expected that they sell their very own lineup of 3D printing pellets. On top of their natural PLA pellets, they also sell a Woodfill version, as well as other materials like ABS, HIPS, ASA, PET, and PMMA. Pollen is also open to engaging with customers who need materials that are beyond what they offer currently.

Final thoughts

3D printing with pellets might seem like a step backward technologically. After all, filaments were specifically designed to make 3D printing easier and more fuss-free. However, it also cannot be argued that the additional processing step makes 3D printing filaments a lot more expensive than their pellet counterparts.

The unfortunate news is that jumping into pellet-based 3D printing isn’t for everyone. With equipment that costs at least $10,000, printing with pellets simply isn’t worth the investment for those who want to get into 3D printing for fun or for those who only use 3D printer for one-off pieces. The technology is already available – it’s now just a question of creating a demand for it.

Warning; 3D printers should never be left unattended. They can pose a firesafety hazard.

PLA Pellets | Filament2Print

PLA pellets are small cylinders composed of PLA Luminy LX175. PLA (polylactic acid) is a biodegradable plastic obtained from natural resources such as starch extracted from corn, sugar beet and wheat.

PLA is one of the most widely used materials in 3D printing today because it does not give off harmful gases and is easy to print.

Image 1: PLA pellets. Source: Filament2print.

The finish of parts 3D printed with PLA stands out for its glossy finish, which makes it a material widely used for the manufacture of aesthetic or decorative parts, as well as for the creation of non-functional prototypes.

PLA pellets are of the highest quality and do not incorporate recycled or reclaimed material. Because of these qualities, PLA pellets are perfect for 3D printing, achieving high print quality. There are several methods for using pellets in 3D printing:

PLA pellets can be used in the manufacture of filament for FDM 3D printers using Filastruder or any other filament extruder.
A pellet extruder can be used directly.

To obtain different colours, the PLA material pellets must be combined with the desired dyes. In this way, customised colours can be achieved. This can be very useful, as in some cases it can be difficult to find the exact colour required for each application. This is a great advantage, especially when producing small series of parts in a particular colour.

Image 2: Examples of dyes for pellets. Source: Filament2print..

With the combination of PLA Pellets and a good filament extruder such as Filastruder, it is possible to obtain 3D printing filament with qualities similar to those of a commercial PLA filament.

When using PLA Pellets to make filament with a filament extruder such as Filastruder or using a pellet extruder for direct 3D printing, it should be noted that the extrusion temperature must be regulated in relation to the extrusion speed used.

The temperature suitable for extruding these pellets in Filastruder PLA is between 220 and 230C. For higher speeds can be increased extrusion temperature to 240 ° C,but in this case there is a risk of small air bubbles appearing in the filament. For optimal results, it is recommended to read the product's usage tips.

Tensile strength (MPa)	60
Tensile modulus (MPa)	3500
Flexural strength (MPa)	83
Flexural modulus (MPa)	3800
Biodegradable	Biodegradable

The temperature suitable for extruding these pellets in Filastruder ABS is between 220 and 230C. For higher speeds can be increased extrusion temperature to 240 ° C, but in this case there is a risk of small air bubbles appearing in the filament.

It is very important to store PLA pellets in an airtight bag to prevent them from absorbing moisture from the environment before use. If the pellets have moisture in them, the filament to be manufactured may contain small imperfections. Once the filament has been manufactured using PLA pellets, it is also recommended to store the filament in a dry place or in an airtight bag. This prevents the filament from absorbing moisture, thus obtaining better results during 3D printing.

Material	PLA
Format	1 Kg bag 5 Kg bag 15 Kg bag
Density (ISO 1183)	1.24 g/cm³
Colour	Natural
Izod impact resistance	-
Charpy impact resistance	-
Ultimate breaking strength (D882)	6 %
Maximal deformation at break	-
Tensile strength (D882)	60 MPa
Tensile modulus (D882)	3500 MPa
Bending strength (D790)	83 MPa
Bending modulus (D790)	3800 MPa
Surface hardness	-
Processing temperature	200-240 ºC
Glass transition temperature	60 ºC
Melting temperature	-
MFR Ratio	28g/10min @ 220°C/10. 0Kg
HS Code	3901.1

* The typical values listed in this table should be considered as a reference. We advise you to confirm the final results and properties with your own tests. For further information please refer to the product data sheet.

How plastic for 3D printing is produced / Sudo Null IT News

REC, a manufacturer of consumables for FDM printers, will become an exhibitor at 3D Print Expo. While we are making final preparations for the exhibition, we asked the guys to show how their production process goes. Under the cut - a story with photos.

Extrusion line control panel. Parameters for filament extrusion are set here (clickable)

The sixth 3D Print Expo will be held in Moscow on October 12-13. There will be a lecture hall, master classes and a drawing of prizes. See the full list of participating companies here. The program of the event can be found here.
We talked about the content of the master classes in one of the previous posts.

The production workshop of REC is located in the Kalibr Technopark on Alekseevskaya. The floor area is one and a half hundred square meters. Half of the space is occupied by three extrusion lines where products are made. The remaining half is accounted for by the packaging workshop and the warehouse for finished products. All production is served by five people.

There is almost no smell here - the exhaust system is responsible for this. From six points, it takes air with throttles and sends it through the filter to the ventilation system. Chokes are installed above each extrusion head and each coil.

On the other hand, as in any production room, it is quite noisy here: firstly, the extruders themselves are noisy. Secondly, a large number of fans and convectors work.

Feedstock is purchased in the form of granules. They come in 25 kg bags or 750 kg oktobins (large corrugated cardboard packages). The granules are cleaned to get rid of household waste and mixed with the dye granules. Additional additives can be added to give the plastic the desired properties. After mixing, the raw materials are sent for drying in the following drying bins:

Each hopper holds 75 kg of pellets. For each polymer, the drying time will be different. For example, ABS dries for 3 hours at 70 degrees, and polycarbonate for 3.5 hours at 120 degrees.

Mixing and drying is always done the night before. During the night, the raw material dries up, and in the morning it is ready to be sent to the extruder. There it is transferred by automatic loaders.

Inside the extruder, a screw rotates under high pressure and temperature - it carries the granules. The walls of the extruder are heated to the right temperature and they turn the pellet into a melt. At the outlet under pressure, it is formed by the extrusion head into the correct thread - strand. The main task of the technological process is to make it perfectly even and straight, without drops. Each polymer has its own technological map, with the desired temperature and speed.

After the extruder, the plastic is cooled in water baths and enters the diameter and broach control unit.

Diameter and broach control unit. The device controls the specified diameter of the bar (clickable)

Winding device (clickable)

The thread passes laser measurements and is wound first on a large drum, and then rewound on spools - kilogram, two kilogram, etc.

Large drum winder

Then these blanks are placed in a convector drying oven and packed in vacuum bags.

The speed of production of different polymers can be very different, from 3 to 10 kg per hour on one line. This depends on the properties of the plastic, and the melt flow rate plays a decisive role. For example, PLA is produced at a rate of ~7 kg per hour. After production, the coil is sent to the drying cabinet and spends there from 4 to 24 hours (depending on the type of plastic).

REC produces more than 20 different materials, but stores only sell 11

their list

ABS, PLA, HIPS, FLEX(TPE), RUBBER, RELAX (PETG), ETERNAL (ASA), PVA, CAST (PMMA), SEALANT (TPU), FRICTION (PA

The rest of the materials are made on special orders for manufacturing organizations.

PLA plastic for 3D friend, 20 colors, lower prices, retail and wholesale.

Find a cheaper price BARGAIN, I'll get the best price in Ukraine!

PLA plastic recommended for other high current applications with minimal shrinkage.

Advantages of PLA plastic:

1. Low shrinkage, high stability of finished molds.

2. Pull the surface of the overlaid with PLA-plate of the virobi

3. The details are good, it is a simple to the PROPRACUVANNA of the Scholofuvanni, they do not vimagayu of the special functions of

4. Easily metallized, with a low coefficient of rubbing, through which it is often victorious for forging bearings.

5. Eco-friendly material (both for the authorities and for the preparation cycle). When heated, one does not see the shkidlivyh speeches.

And Know Vi, Shcho:

Yakshcho Part PLA plastic elalcetate (Penzlik, lumps, burdens), then vin -elastic yak guma I so flood the Trivaliy Termin (can be able to surpass) after repeated evaporation of ethyl acetate.

PLA plastic is ideal for making casting molds for casting metals, so it can have practically zero ash content and low furnace temperature.

Hygroscopicity and drying.

Zej plastic is more hygroscopic. According to the statements of the syrovin (granules) maker, before the processing (melting) of drying, the plastic can be rebuffed for no more than 1.