Reprap Forum - Wire and Thread Embedded Extrusion Add a new print head to the Reprap, capable of laying wire/thread materials directly from a spool into a printed part! https://reprap.org/forum/list.php?143 Mon, 10 Aug 2026 00:33:41 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?143,445114,445114#msg-445114 Printing woven structures in fibrous materials (no replies) https://reprap.org/forum/read.php?143,445114,445114#msg-445114 Printing woven structures in fibrous materials



I imagine the yarn could be replaced with copper wire, resin coated and UV cured to create large embedded objects.

[www.instructables.com]

[www.3ders.org]
]]> A2 Wire and Thread Embedded Extrusion Thu, 18 Dec 2014 07:40:05 -0500 https://reprap.org/forum/read.php?143,427707,427707#msg-427707 3D printed magnet coils (3 replies) https://reprap.org/forum/read.php?143,427707,427707#msg-427707
I have not looked recently if this has been discussed but a year ago I don't remmber that is was standard operating procedure.

However 2 days ago I read something from a company tht sells manet wire (so called enamelled copper wire) that was news to me. Now seeing this section on the forum made me want to comment here just incase it has not been discussed.

What I am talking about is self supporting coils. These are to be found most often in pancake motors and and hard drive voice coils. I have wondered in passing how much trouble it must be to make them by haaving to wind then and then impregnate them with varnsh and then wait fr them to dry withut disturbing the coil shape. Turns out I was behind the times. There is a rnge of magnet wires that have a outer layer of 'varnish' that is a bonding or adhesive layer. It is activated by solvent or heat, the heat can be supplied with a hotair gun at the time of winding or after compltion or they can be baked in an oven at a specific temperature. They are also sometimes resistance heated by passing a current (or I suppose they could be heated with an AC magnetic field if the winding is shorted out first) though them. This is interesting because the same wire could be printed with a RepRap machine and bonded as you go wiith heat (hot air desoldering tool) or solvent (Q-tip/ear-bud on an alcohol bottle).

Has anyone heard about this, has it been discussed, could it work???

For less demanding and perhaps lower temperature applications perhaps one could use a thicker polythene, ABS or PLA coated wire that could be heated whle it passs through a standard extruder but this I think may have been discussed though it would still need to have the 'varnished' wire so the turns cannot short even if the wires are pushed together. This bondable magnet wire oes seem interesting.

Here are a couple of random links I found while I was finding out about it, there are more, it is just a case of using the correct search terms.

[www.mwswire.com]
[www.superioressex.com]
[www.elektrisola.com]]]> KalleP Wire and Thread Embedded Extrusion Tue, 14 Nov 2017 08:44:52 -0500 https://reprap.org/forum/read.php?143,399412,399412#msg-399412 Fiber Composite 3D Printing (The Bug) (1 reply) https://reprap.org/forum/read.php?143,399412,399412#msg-399412 Fiber Composite 3D Printing (The Bug), by Sebastian Morales

[www.instructables.com]
[www.youtube.com]
[www.adorevolution.com]
[www.youtube.com]



]]> A2 Wire and Thread Embedded Extrusion Sun, 07 Dec 2014 12:26:29 -0500 https://reprap.org/forum/read.php?143,360061,360061#msg-360061 Additive wire laying (18 replies) https://reprap.org/forum/read.php?143,360061,360061#msg-360061 I recently did some experimenting with additive wire laying. I use a slew drive, concentric with the nozzle, to guide a copper wire under and just in front of the nozzle. The slew drive rotates in the direction of movement, and thus I'm able to embed the wire under plastic. In short: additive way of making copper traces.
I hope you have a use for it. I've put some more info on my blog. There's also the link to the YouTube video.
[basdebruijn.com]
Regards,
Bas]]> basdebruijn Wire and Thread Embedded Extrusion Sat, 04 Jul 2015 22:15:06 -0400 https://reprap.org/forum/read.php?143,356549,356549#msg-356549 3DXNano conductive carbon nanotube filament, resistance? (no replies) https://reprap.org/forum/read.php?143,356549,356549#msg-356549
I'm new here so I hope this is the right place, else please move to another section. Sorry / Thanks.

I just found this article about 3dxtech.com releasing a conductive carbon nanotube filament:
[3dprint.com]
[3dxtech.com]
$62 for a kg.

Anyone can explain to me what "Target conductivity for 3DXNano™ ESD ABS: 10(7) ohm/sq surface resistivity" means?
Is that "107 Ohm * Meter" (on a 1 square meter block)?
From what I read on wikipedia, conductivity is the inverse of resistivity, and both are usually defined by ohm and meters.
Does that mean 1 cubic meter of the stuff would have 100 MOhm?

[en.wikipedia.org]

PS: This article [www.plosone.org] says about "carbon black" that:
"The measured resistivity of the composite in-plane with the layers was 0.09±0.01 ohm m−1"
Which confuses me further since the unit given on wikipedia says Ohm * m, but I guess really it's Ohm * m / m2 which would be Ohm / m. Am I obtuse or is this confusing?

PPS: I send them an email hopefully they get back to me.

PPPS: After checking out [www.rabbitproto.com] I realize this is apparently "sheet resistance", not "bulk resistivity"...
[en.wikipedia.org]
Can someone ELI5 this for me? (Explain like i'm 5). If I print a 1cm strang of 0.4 mm thickness, how much Ohm would that be?

PPPPS: They updated the website to state that "Target conductivity for 3DXNano™ ESD ABS: 1.E7 to 1.E9 ohm surface resistivity on 3DP sample per standard outlined in ASTM D257.".]]> Dejay Wire and Thread Embedded Extrusion Sat, 17 May 2014 16:14:42 -0400 https://reprap.org/forum/read.php?143,338671,338671#msg-338671 Elastic electronics: Stretchable gold conductor, University of Michigan (no replies) https://reprap.org/forum/read.php?143,338671,338671#msg-338671
The team was surprised that spherical gold nanoparticles embedded in polyurethane could outcompete the best of these in stretchability and concentration of electrons.

The team made two versions of their material—by building it in alternating layers or filtering a liquid containing polyurethane and nanoparticle clumps to leave behind a mixed layer. Overall, the layer-by-layer material design is more conductive while the filtered method makes for extremely supple materials. Without stretching, the layer-by-layer material with five gold layers has a conductance of 11,000 Siemens per centimeter (S/cm), on par with mercury, while five layers of the filtered material came in at 1,800 S/cm, more akin to good plastic conductors.

Even when close to its breaking point, at a little more than twice its original length, the layer-by-layer material still conducted at 2,400 S/cm. Pulled to an unprecedented 5.8 times its original length, the filtered material had an electrical conductance of 35 S/cm—enough for some devices.

Kotov's team is exploring various nanoparticle fillers for stretchable electronics, including less expensive metals and semiconductors.

"It's just the start of a new family of materials that can be made from a large variety of nanoparticles for a wide range of applications."

[phys.org]]]> A2 Wire and Thread Embedded Extrusion Sat, 12 Apr 2014 00:38:47 -0400 https://reprap.org/forum/read.php?143,255454,255454#msg-255454 Fibre Core co-extrusion (3 replies) https://reprap.org/forum/read.php?143,255454,255454#msg-255454
[reprap.org]

The two concepts are winding the thread around the plastic so the correct amount goes into the melt zone so it will exit at the correct nozzle extrusion speed the other is some thoughts on a coaxial nozzle that would work much like a wire insulation machine but much slower.

Interestingly I saw a machine that is used to make flux cored solder a couple of months back. It is a solid solder extruder that presses a billet of metal through an annular nozzle. The centre is continuously filled with molten flux as the solder extrudes. They had it easy because the diameter on exit was about 7-10 mm. It was then fed through two progressive wire drawing machines that stretched and thinned the cored solder to sizes from 2.4 to 0.5 mm. The interesting thing to note was that the extruding solder did not try and push into the flux feeder, it rather drew the flux down into the hollow tube with gravity and created partial vacuum.

Have a look and discuss if interested.

It is a concept I am personally unlikely to test but it might be just the thing someone needs.]]> KalleP Wire and Thread Embedded Extrusion Fri, 08 Jul 2022 11:29:04 -0400 https://reprap.org/forum/read.php?143,185513,185513#msg-185513 Pultrusion (1 reply) https://reprap.org/forum/read.php?143,185513,185513#msg-185513
[en.wikipedia.org]

[www.pultrusions.org]

Now even though pultrusion is meant to form constant cross-section parts, it seems like it could still be compatible with the 3d printing extrusion approach which is simply laying down an extrusion stream in a complex continuous pattern that adds up to some arbitrary part geometry.

I'd like to ask about continuity of an extrusion stream vs continuity of an embedded fiber. Even if we assume that any arbitrary part geometry can be printed out using a single continuous extrusion stream, is a single embedded continuous fiber all along that extrusion path the desired goal for maximizing the strength of the final printed part?

If not, then how does the desired fiber geometry differ from the conventional extrusion path used to achieve the geometry of the printed part?]]> sanman Wire and Thread Embedded Extrusion Mon, 18 Feb 2013 02:30:00 -0500 https://reprap.org/forum/read.php?143,159545,159545#msg-159545 Fused Deposition Modeling of Metals (3 replies) https://reprap.org/forum/read.php?143,159545,159545#msg-159545
[utwired.engr.utexas.edu]]]> Have Blue Wire and Thread Embedded Extrusion Sun, 10 Feb 2013 14:19:10 -0500 https://reprap.org/forum/read.php?143,114379,114379#msg-114379 Conductive paint extrusion (3 replies) https://reprap.org/forum/read.php?143,114379,114379#msg-114379 metzindustries Wire and Thread Embedded Extrusion Sun, 18 May 2014 13:26:37 -0400 https://reprap.org/forum/read.php?143,59565,59565#msg-59565 iron powder extruder (4 replies) https://reprap.org/forum/read.php?143,59565,59565#msg-59565 i been working in a model of extruder that can work with iron powder (ultra fine grained ) melting with magnetic field. i have a little testing model working but i am interested if somebode in Uruguay has a reprap to test my little metal extruder.
The deployment is in early alpha and i am still making the electronic controller to make the depositation of melted metal secure and equal every pass.
Soon i will put schematics and pictures.
Greetings
MARTIN]]> zerodmg Wire and Thread Embedded Extrusion Sat, 18 Jun 2011 12:00:02 -0400 https://reprap.org/forum/read.php?143,42935,42935#msg-42935 Alpha release (10 replies) https://reprap.org/forum/read.php?143,42935,42935#msg-42935
[reprap.org]

CAD files up, a few mechanical drawings and software files to follow.

Much work still remains to be done, so don't jump on and expect to start printing circuits. But if you're interested in doing development work on the SpoolHead, the files are there for you.]]> jbayless Wire and Thread Embedded Extrusion Sun, 17 Feb 2013 13:34:39 -0500 https://reprap.org/forum/read.php?143,40582,40582#msg-40582 Wire Feeding Video (no replies) https://reprap.org/forum/read.php?143,40582,40582#msg-40582
[www.youtube.com]


The wire might look like it's going slowly, but we only need to propel the wire a very short distance by this method. Once it's bonded to the part, we can hold the pencil button down and very rapidly pull out more wire using tension, just by moving the head about.


Jacob]]> jbayless Wire and Thread Embedded Extrusion Fri, 26 Mar 2010 01:56:03 -0400 https://reprap.org/forum/read.php?143,39772,39772#msg-39772 Major Software Tasks (3 replies) https://reprap.org/forum/read.php?143,39772,39772#msg-39772
For our project, we're just going to hand-craft the G-code to print models with wires in them. To do this, we'll start with an STL file, G-codeify it, and then insert the relevant wire G-code by hand.

It's a labour-intensive, machine-specific process that's not fit for the future adoption of this printing technology. You wouldn't be able to upload a G-code file with wires in it to Thingiverse, for example.

What we ideally need is:
- A 3D file format that can support these structures. It could amount to a very simple modification of the STL format, actually; wires could be no more than polylines in 3D space, which would be very simple to represent and process (just a string of XYZ points, really).
- A 3D modelling program that will let you create and store polylines in a model. If you've used SolidWorks, it might be just a matter of creating 3D sketches to represent wires, in addition to the solid part. But we'll need open-source software that can do this, because SolidWorks won't let you reprogram it, and Dassault Systems is not likely to respond to our feature requests. ;)
I'd be surprised if Blender could do something like this. Perhaps we'll have to wait on the numerous open-source CAD programs to be released?
- A plug-in for slicing programs like Skeinforge and Host, to generate wire G-code from the polylines.

All three are quite significant tasks. The scope of the SpoolHead project is to create workable hardware and firmware for printing wires into parts. But you won't see parts with wires in them popping up on Thingiverse until these software tasks have been tackled.

Of course, if Reprap is to accomplish multi-material (or colour) printing at all, we're almost definitely going to have to move beyond the STL format. It might be a good idea to start thinking of what's going to replace it. So I, for one, would nominate 3D polylines be considered as an important feature.

Jacob]]> jbayless Wire and Thread Embedded Extrusion Sat, 20 Mar 2010 05:48:17 -0400 https://reprap.org/forum/read.php?143,38373,38373#msg-38373 Wire wrap (6 replies) https://reprap.org/forum/read.php?143,38373,38373#msg-38373 wire wrapping.
This was a favored method of early prototyping circuits.
Same method can be applied here.
Pcb you would use is veroboard/stripboard or perfboard, all these options are really, really easy to get a hold of.

Debate and discuss?]]> Grogyan Wire and Thread Embedded Extrusion Tue, 09 Mar 2010 03:13:51 -0500 https://reprap.org/forum/read.php?143,38324,38324#msg-38324 Use plastruder to secure wire? (no replies) https://reprap.org/forum/read.php?143,38324,38324#msg-38324
The idea would be for the spoolhead tool to emit wire on to the object, and have the plastruder then cover it up with plastic to bond it to the object.]]> KevinOConnor Wire and Thread Embedded Extrusion Sun, 07 Mar 2010 12:30:06 -0500 https://reprap.org/forum/read.php?143,37831,37831#msg-37831 Fiberglass thread extruder (15 replies) https://reprap.org/forum/read.php?143,37831,37831#msg-37831
The extruder will have to be more carefully constructed because the thread will easily bend and jam, it should still be possible to make a pinch roller system with rubber or silicone rollers to push the thread out the opening. To cut off one section after laying it down a scissors type device would work best, actuated by a small servo motor. If the previous layer of ABS is still soft, it might be possible to press the thread against it to tack down each end. Or the mouth of the fiberglass extruder would have a hot surface to remelt the ABS, stick the fiberglass in quickly, let it re-harden before moving the head, then stop at the other end and repeat the process to tack down the other end. Or it might be best to extrude a little bit of ABS along with the fiberglass so that it immediately attaches to the plastic and is not pushed out of the way when the next layer of plastic is extruded.

Fiberglass should be very easy to lay down in X and Y dimensions, but I have no idea at this point in how to work it in the Z dimension and layers are being built up. I think the best way at this point to get three dimensional strength from fiberglass reinforced ABS is to build a cap or side piece that is rotated 90 degrees and laying down on the bed, then glued on later. Like the plastic itself, the fiberglass should be laid down in different directions for each layer to give greater strength and dimensional stability.

I have made a quick Google search for fiberglass thread, cord, yarn, string, and all I could find was sewing thread that is PTFE coated. This will not work well because the PTFE (Teflon) will not bond at all with the ABS, and the thread will just pull through the body of the plastic parts without giving them any extra strength.

If we are going to make a very large fraction of a reprap out of RP plastic parts, strengthening them and keeping them from bowing or bending under pressure will become critical. ABS is already one of the better plastics to use for structural strength, but I don't think that long structural pieces of it will remain straight for years. I have seen even fairly large diameter ABS pipes bow after awhile.


Mike]]> rocket_scientist Wire and Thread Embedded Extrusion Fri, 24 Jan 2014 00:58:38 -0500 https://reprap.org/forum/read.php?143,34269,34269#msg-34269 Another 'wire securing' technique (6 replies) https://reprap.org/forum/read.php?143,34269,34269#msg-34269 the discussion page on the wiki.

My first thought was to snap the wire in, but it could also secure it by zig zagging it thru alternating small printed overhangs to allow it to be secure enough to print another layer on top of it to secure it more firmly.]]> BeagleFury Wire and Thread Embedded Extrusion Thu, 03 Mar 2011 15:53:19 -0500 https://reprap.org/forum/read.php?143,33326,33326#msg-33326 ReplicatorG and Multiple extruder controllers (2 replies) https://reprap.org/forum/read.php?143,33326,33326#msg-33326
One challenge we are currently facing is we are not sure how multiple extruders can be controlled using ReplicatorG.

Our plan was to use one extruder controller to control the thermoplastic extruder that everyone is familiar with, and a second extruder controller to control a head that lays down wire. Hence, we would be taking advantage of the existing firmware of the extruder controller.

However, after much searching, we still could not find information on how this is done, even though the ReplicatorG website states, "more codes exist now for controlling build platform temperature, case temperature, a second extruder, and for controlling stepper motors on extruders." (http://replicat.org/mcodes)

If anyone has tried to program two extruder controllers connected to a single motherboard, it would be awesome if you could let us know how you did it.

We will post updates on this problem here.

Thanks.
Mo]]> mochen72 Wire and Thread Embedded Extrusion Thu, 21 Jan 2010 04:42:34 -0500 https://reprap.org/forum/read.php?143,33209,33209#msg-33209 UV-triggered epoxy (1 reply) https://reprap.org/forum/read.php?143,33209,33209#msg-33209
It's easy to turn on and off. There's some threads in the forum on it, I think.]]> SebastienBailard Wire and Thread Embedded Extrusion Tue, 26 Jan 2010 01:40:04 -0500 https://reprap.org/forum/read.php?143,33201,33201#msg-33201 Weekly Progress (14 replies) https://reprap.org/forum/read.php?143,33201,33201#msg-33201
We're filling out weekly progress reports as part of our university project requirements. I thought I'd post them here too, since reading it might help others with their project planning.

Reporting period: Jan 04 to Jan 10


1.) Is your project on schedule? No
Mechanical assembly of the Reprap is nearly complete, but electronics and testing has not begun. This is expected to take about one week. Schedule had ambitiously estimated that test printing would be conducted this week.

2.) What did your group members accomplish during the past week?
- Prepared parts for Reprap 3D printer (drilling and tapping holes, cutting rods, sanding parts).
- Began mechanical assembly of Reprap 3D printer. Mechanical assembly is now about 90% complete. Printer X, Y, and Z axes are built, awaiting the addition of timing belts and a replacement shaft coupler. Extruder construction and electrical system assembly has not yet begun.

3.) What problems, if any, did you encounter?
- Printed part holes were slightly undersized, requiring them to be drilled out (although this brought the advantage of creating a smoother bore). This made the assembly more labour-intensive and time-consuming than expected. As well, several parts did not fit together without significant sanding and filing (we later learned that boiling water can be used to soften these parts to help them fit).
- Due to out-of-date documentation, we drilled out some diagonal-bracket holes which were meant to be interference fits, making the parts loose. This problem was fixed by bandsawing a slot in these parts to create a split ring, which when tightened produces a strong grip. We believe this split-ring design is superior to the original interference fit, and so we will release it to the Reprap community as an improvement to the Darwin design.

- We were lacking a part required to splice the Z-belt, and one of the shaft couplers was misaligned. On Saturday, Bing and Jacob visited Wade and obtained the belt-splicing jig, as well as a replacement shaft coupler. Therefore, assuming the replacement coupler functions correctly, Cartesian assembly is expected to be completed this Monday Jan 11th. Electrical system construction and testing has not yet begun, so the project is behind schedule.
- Extruder components, ordered one month ago, have not yet arrived. We are concerned that they may be delayed at the border due to heightened Olympic security. If these do not arrive on time, replacements will need to be machined on the premises. This is do-able, but will consume additional time.

4.) What are your main goals for the week?

Construction of the extruder and electronics, and testing of the Reprap system.


5.) How much time did each member spend on project work in the past week?
[This figure excludes time spent in during winter break, from Dec 28 to Jan 04, estimated at an additional 20 hours per team member].
Mo Chen / 18 hours
Jacob Bayless / 18 hours
Bing Dai / 18 hours]]> jbayless Wire and Thread Embedded Extrusion Mon, 05 Apr 2010 02:38:50 -0400 https://reprap.org/forum/read.php?143,32944,32944#msg-32944 Wire and Thread Embedded Extrusion, Introducing a new research project! (3 replies) https://reprap.org/forum/read.php?143,32944,32944#msg-32944 Hey Sebastien,

I'm part of a team of three engineering physics students, and we're doing a project course. Our project is to add a new print head to the Reprap, capable of laying wire/thread materials directly from a spool into a printed part. The applications of this would be to print copper wires for cable routing, coils for motors/antennas/electromagnetic components, and connectors; or to print steel reinforcement wires, or (maybe) sewing thread 'living hinges' for flexing parts. We're about 90% done construction of our Darwin base model, and soon to begin on the print head. We should be finished the whole project by mid March.

A big part of our project is, of course, the documentation. We're keen to release it open-source for the Reprap community to benefit. But I have a very vague idea of how we'd actually release it back to the community. My guess was that we'd have to start a blog, like Nophead's HydraRaptor or the other guys, and pipe it in. But that seems like it will only exacerbate the problem of decentralized documentation.

So, where should documentation for our project properly go to be most useful?

Jacob

Jacob, thank you a thousand times for asking! I've create a new forum:
[dev.forums.reprap.org]

This will be a good entry point for other people and kibbitzers, and provide a community hub 10 years from now when you three are floating around in a space station, having handed over the project to someone else.

I'd also create a dedicated mailing list welded onto the forum, but I can't for the next week or two. Use the most comfortable comms system you like, it can be tedious to try to interface a mail client with the forum so I don't expect you guys to have to.

You should probably start your own blog somewhere, that way you've got good fodder for your c.v./resume, and that makes your project more mediagenic. I'd offer you a blog like "SpoolHead.RepRap.org" but we don't have that functionality yet.

Here's a wiki page mockup, with the working title "SpoolHead" which you can move to a better name.
[objects.reprap.org]

Until we have a better system, you may want to store parts like "Foo" in
[objects.reprap.org].

The other devs and I have got an email in my folders somewhere from an Israeli who figured it out a decade or two ago and wanted to donate ?his/her? ?kevlar?/epoxy thread/binder system.

We completely dropped the ball on that, and he probably figures we blew him off. Let me know if you want me to dig up that email.

I've quoted your email in its entirety, as it didn't seem to be sensitive/private. I hope that's ok; let me know if it isn't.]]> SebastienBailard Wire and Thread Embedded Extrusion Sun, 01 Nov 2015 12:49:07 -0500