Stackable, printed extrusions that can be filled with resin I have published a design on thingiverse that are stackable extrusions that you can print out at 0% infill, and fill the cavity with resin. It's a work in progress, but it's nearly finished after going through a few revisions. The thingiverse has a detailed description. https://www.thingiverse.com/thing:2876264 Thank you for reading and taking a look :) https://reprap.org/forum/read.php?1,820261,820261#msg-820261 Thu, 10 Sep 2026 21:55:13 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?1,820261,820595#msg-820595 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820595#msg-820595
Quote
Origamib
Quote
klcjr89
Quote
o_lampe
Why did you choose 50mm height? Is that your printers max. height? I think, making them as long as possible will reduce the number of contact areas ( read: chances of misalignment )

It was done to keep possible print failures at a lower point instead of printing a 300mm tall extrusion and have it fail and waste plastic.

I'f you're worried about adhesion... get creative. Add some ribs to the design that are a single extrusion thick (0.48mm in my case) and then cut them off with a sharp blade. Add a brim for extra strength.

I think I'll stick to the original plan since the printer can clear its own bed of parts for automation. This will be detailed in another thread sometime in the future after more testing :)]]> klcjr89 General Sun, 29 Apr 2018 09:47:38 -0400 https://reprap.org/forum/read.php?1,820261,820581#msg-820581 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820581#msg-820581
Quote
klcjr89
Quote
o_lampe
Why did you choose 50mm height? Is that your printers max. height? I think, making them as long as possible will reduce the number of contact areas ( read: chances of misalignment )

It was done to keep possible print failures at a lower point instead of printing a 300mm tall extrusion and have it fail and waste plastic.

I'f you're worried about adhesion... get creative. Add some ribs to the design that are a single extrusion thick (0.48mm in my case) and then cut them off with a sharp blade. Add a brim for extra strength.

]]> Origamib General Sun, 29 Apr 2018 08:19:00 -0400 https://reprap.org/forum/read.php?1,820261,820529#msg-820529 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820529#msg-820529
Quote
klcjr89
Quote
o_lampe
You'd have to cut the ends very precise, before stacking them.
This hasn't been an issue at all. Ready to go straight off a well-tuned delta printer.

Quote

It was done to keep possible print failures at a lower point instead of printing a 300mm tall extrusion and have it fail and waste plastic.

What now? Do you have a well tuned Delta or not? ;) You'd need gooood bed adhesion too.]]> o_lampe General Sun, 29 Apr 2018 02:05:18 -0400 https://reprap.org/forum/read.php?1,820261,820528#msg-820528 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820528#msg-820528
Quote
o_lampe
Why did you choose 50mm height? Is that your printers max. height? I think, making them as long as possible will reduce the number of contact areas ( read: chances of misalignment )

It was done to keep possible print failures at a lower point instead of printing a 300mm tall extrusion and have it fail and waste plastic.]]> klcjr89 General Sun, 29 Apr 2018 02:00:58 -0400 https://reprap.org/forum/read.php?1,820261,820527#msg-820527 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820527#msg-820527 contact areas ( read: chances of misalignment )
I've made airfoils for a vertical windmill 270mm high on my CoreXY. Others will report much taller parts ( tall vases and such )

For my Delta I'm currently inventing a new print mode, I call Tower mode. It didn't work out yet, but I'm close. ( The magnets of the rods are too close to the fans )
It prints the first half of a very tall part in normal mode, then I revers the effector/rod/carrier orientation ( carriers are now below the effector ) and print the upper half of the part. One day I can print parts taller than the Delta frame :)

[attachment 104641 effector_above_frame.JPG]]]> o_lampe General Sun, 29 Apr 2018 01:58:07 -0400 https://reprap.org/forum/read.php?1,820261,820492#msg-820492 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820492#msg-820492
I think that the cutouts might actually work, provided you fill the cavity with resin and sand or other fillers. This would further simplify the design and I can make the extrusion size 50mm in height instead of the oddball 40mm + endcap requirements.

A cutaway view hopefully explains this better than my wording. Where the hex nut and counterbore cutout feature's perimeters bond to the top and bottom layers is one of the weak points, since these areas will be under tension when the internal tube's layers starts to compress from the threaded rod's clamping force.


]]> klcjr89 General Sat, 28 Apr 2018 15:27:54 -0400 https://reprap.org/forum/read.php?1,820261,820476#msg-820476 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820476#msg-820476
Quote
o_lampe
You'd have to cut the ends very precise, before stacking them.

This hasn't been an issue at all. Ready to go straight off a well-tuned delta printer.

Good idea on the sand!]]> klcjr89 General Sat, 28 Apr 2018 12:45:36 -0400 https://reprap.org/forum/read.php?1,820261,820451#msg-820451 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820451#msg-820451
It is also used to create sandwich constructions, so it has to harden in enclosed areas. I used it to fill my tubular chassis with foam, to make it a bit stiffer.
You can also pick out of a variety of cell sizes. Different liquids have different foam characteristics.]]> Lykle General Sat, 28 Apr 2018 05:31:39 -0400 https://reprap.org/forum/read.php?1,820261,820432#msg-820432 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820432#msg-820432
Filling with Resin gets much cheaper by using 95% sand and 5% resin.
Filling with foam and also using 5% infill would improve things alot. The foam can bond with the infill, which makes it much stronger than bonding with the inner surface alone.]]> o_lampe General Sat, 28 Apr 2018 03:19:59 -0400 https://reprap.org/forum/read.php?1,820261,820414#msg-820414 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820414#msg-820414

]]> klcjr89 General Fri, 27 Apr 2018 18:18:04 -0400 https://reprap.org/forum/read.php?1,820261,820409#msg-820409 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820409#msg-820409 klcjr89 General Fri, 27 Apr 2018 17:23:05 -0400 https://reprap.org/forum/read.php?1,820261,820405#msg-820405 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820405#msg-820405 VDX General Fri, 27 Apr 2018 17:12:59 -0400 https://reprap.org/forum/read.php?1,820261,820404#msg-820404 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820404#msg-820404
Quote
klcjr89
Thanks for the info, do you think I could use such 400nm UV LEDs to directly light up the extrusions if I place them within the extrusions?

There's a couple problems with putting LEDs inside the plastic. First and foremost, it won't make the plastic light up like it does when you shine a UV light from outside. The UV doesn't penetrate the plastic to any depth- it makes the surface it hits glow, which would be inside the prints. The light that filters through to the outside will be relatively dim and it won't glow like it's being lit with a black light. The other problem is that the LED's get warm and it will be hard to get the heat out of the plastic (which is a thermal insulator).]]> the_digital_dentist General Fri, 27 Apr 2018 16:49:36 -0400 https://reprap.org/forum/read.php?1,820261,820347#msg-820347 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820347#msg-820347
Quote
klcjr89
Quote
o_lampe
When I use foam for a close gap, I use a mist water sprayer before I inject the foam.

I might try this, as the casting resin is very expensive and the volume required to fill the cavity would be astronomical.

Have you considered using mineral fillers in your resin? Calcite is very cheap!]]> ECJ General Fri, 27 Apr 2018 06:47:59 -0400 https://reprap.org/forum/read.php?1,820261,820329#msg-820329 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820329#msg-820329 mars on the rocks General Fri, 27 Apr 2018 03:26:01 -0400 https://reprap.org/forum/read.php?1,820261,820328#msg-820328 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820328#msg-820328
Quote
mars on the rocks
I got it to cure but it didn't have a top I still got voids though I think this technique might better suit thinner walled objects as far as strength goes but between 3 and 5% infill with 4 shells should be strong enough for a 3d printer and wouldn't use to much more filament

Good to know, thanks for trying it. :) If you see the post I made before your first post, you will see my thoughts on this idea based on calculations I made.]]> klcjr89 General Fri, 27 Apr 2018 03:19:39 -0400 https://reprap.org/forum/read.php?1,820261,820327#msg-820327 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820327#msg-820327 mars on the rocks General Fri, 27 Apr 2018 03:15:34 -0400 https://reprap.org/forum/read.php?1,820261,820326#msg-820326 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820326#msg-820326
Quote
mars on the rocks
I've printed the 30x30 and filled it with foam and as a test I printed it again with 5% infill and its seems just as strong.

Did the foam actually cure without voids or did it turn out like the 60x60 extrusion I posted earlier in this thread? Photo is in that post.]]> klcjr89 General Fri, 27 Apr 2018 03:09:38 -0400 https://reprap.org/forum/read.php?1,820261,820325#msg-820325 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820325#msg-820325 mars on the rocks General Fri, 27 Apr 2018 03:07:33 -0400 https://reprap.org/forum/read.php?1,820261,820324#msg-820324 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820324#msg-820324 alot cheaper to buy aluminum compared to the filament on the basis of 30x30 extrusions. However, with the 60x60 extrusions, it is cheaper to print them (probably not in the long run, see below). Initially, I was going to buy 60x60 aluminum ones from Misumi but after seeing the price, I came up with this idea.

Time and electricity is another thing; to print a printer of the_digital_dentist's style that is 1800mm tall and 894mm wide (size that I was planning to build), I calculated it to take at least 713 hours, or 29.7 days non-stop! And that assumes no failures of any kind. These calculations didn't include the time to print the Z axis extrusions either, only the four vertical posts and twelve horizontal extrusions. These calculations were done for the 30x30 size of extrusion.

I think the idea is still valid for smaller projects, provided you want something in a unique color.]]> klcjr89 General Fri, 27 Apr 2018 02:56:10 -0400 https://reprap.org/forum/read.php?1,820261,820312#msg-820312 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820312#msg-820312
Quote
o_lampe
When I use foam for a close gap, I use a mist water sprayer before I inject the foam.

I might try this, as the casting resin is very expensive and the volume required to fill the cavity would be astronomical.]]> klcjr89 General Fri, 27 Apr 2018 02:07:16 -0400 https://reprap.org/forum/read.php?1,820261,820308#msg-820308 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820308#msg-820308 o_lampe General Fri, 27 Apr 2018 01:58:48 -0400 https://reprap.org/forum/read.php?1,820261,820297#msg-820297 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820297#msg-820297 klcjr89 General Thu, 26 Apr 2018 23:30:29 -0400 https://reprap.org/forum/read.php?1,820261,820296#msg-820296 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820296#msg-820296
Quote
the_digital_dentist
I bought a bunch of 1W UV LEDs (get the cheap ones- 400 nm- the 360 nm cost a LOT more and don't cause any brighter fluorescence), a couple strip type PCBs, and then mounted them on aluminum angle stock to direct the light and dissipate heat. I power them with a $8 dc-dc converter set for about 19V out which puts about 20W into the 30 LEDs so they'll live a long, happy life. See [drmrehorst.blogspot.com] I put a few in the top of the machine pointing down on the bed and then two long vertical strips on either side of the clear PC front panel. The way I have arranged the lights you can't see them directly when you look into the front of the printer, but they reflect off the walls very nicely and give a nice effect in photos.

This pictures is with the original UV LED strips I used which were not bright enough, and before I added light to the top of the printer.

I have about 18W of white LEDs arranged on the top and alongside the vertical UV lights in the front of the machine.

Thanks for the info, do you think I could use such 400nm UV LEDs to directly light up the extrusions if I place them within the extrusions?]]> klcjr89 General Thu, 26 Apr 2018 23:25:11 -0400 https://reprap.org/forum/read.php?1,820261,820295#msg-820295 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820295#msg-820295 drmrehorst.blogspot.com] I put a few in the top of the machine pointing down on the bed and then two long vertical strips on either side of the clear PC front panel. The way I have arranged the lights you can't see them directly when you look into the front of the printer, but they reflect off the walls very nicely and give a nice effect in photos.

This pictures is with the original UV LED strips I used which were not bright enough, and before I added light to the top of the printer.



I have about 18W of white LEDs arranged on the top and alongside the vertical UV lights in the front of the machine.


]]> the_digital_dentist General Thu, 26 Apr 2018 23:14:07 -0400 https://reprap.org/forum/read.php?1,820261,820293#msg-820293 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820293#msg-820293
Quote
the_digital_dentist
I've put UV LEDs inside fluorescent plastic parts before and it was very disappointing. The UV makes the surface it hits glow, but it doesn't penetrate the plastic, so the effect is very weak.

I print using fluorescent filament at Maker Faires and have about 20W of UV LEDs installed in my printer. I like to use FoxSmart Screamin' Green TPU but that pink stuff looks really nice, too. I'll have to get some.

I was thinking of just aiming a high power blacklight at the printer, but that would probably not be allowed at a convention/festival if I were to bring the printer there.

I'm trying to persuade 3DXtech to make the same as the pink, but in a blue color. No word on that yet.]]> klcjr89 General Thu, 26 Apr 2018 22:27:48 -0400 https://reprap.org/forum/read.php?1,820261,820292#msg-820292 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820292#msg-820292
I print using fluorescent filament at Maker Faires and have about 20W of UV LEDs installed in my printer. I like to use FoxSmart Screamin' Green TPU but that pink stuff looks really nice, too. I'll have to get some.]]> the_digital_dentist General Thu, 26 Apr 2018 22:14:01 -0400 https://reprap.org/forum/read.php?1,820261,820291#msg-820291 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820291#msg-820291
Quote
the_digital_dentist
That does look nice! Who makes the filament?

Thanks! 3DXTech is the manufacturer (all USA based, thankfully.)

I was thinking about modeling a channel into the extrusion so I could put high intensity UV leds hidden inside the extrusion, but am not sure how well the light would be diffused. Would also be interesting to see if resin would help diffuse the light. I would probably design a PCB and place the UV leds on it that way it can be more easily inserted into the extrusions. I would probably get the PCBs made through OSHPark.

:)]]> klcjr89 General Thu, 26 Apr 2018 21:15:28 -0400 https://reprap.org/forum/read.php?1,820261,820290#msg-820290 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820290#msg-820290 the_digital_dentist General Thu, 26 Apr 2018 21:11:06 -0400 https://reprap.org/forum/read.php?1,820261,820289#msg-820289 Re: Stackable, printed extrusions that can be filled with resin https://reprap.org/forum/read.php?1,820261,820289#msg-820289
Quote
the_digital_dentist
Have you calculated the cost of this "extrusion" compared to aluminum?

On the basis of the 60x60 extrusion I planned to purchase from Misumi, it costs less for me to print the extrusions and that is with high-quality pricier filament than the bargain bin no name filaments. For smaller extrusion sizes, it may or may not be worthwhile; I did not calculate the price difference.

I'm not doing it on the basis of cost, but rather to make something unique. The idea started for building a printed pink panther printer for cancer awareness.

The filament is UV sensitive metallic sparkle pink and it looks amazing under a blacklight: B)


]]> klcjr89 General Thu, 26 Apr 2018 21:06:18 -0400