Imagine a Simpson type format robot with the ability to shape metal into near net shape. I propose such a robot could use 2 simple toolheads to accomplish this: One tool head equipped with a wire feed (much like a filament feed) and a cutting solenoid. This tool head would push out wire downward into a bed of styrofoam (or other material that would hold the wire) at varying lengths, depending on the topography of the part being printed. Each XY coordinate on the print bed would be handled this way until a "bed of needles" is formed with the rough topography of the part being made. The second tool would be equipped with a small propane torch and a tiny ballpoint hammer, actuated by a solenoid. After the first tool is done placing each wire, the group of wires would be clamped together. Then the second tool would be used to heat and then hammer the wires downward into the final shape of the part. Each small hammer blow would "upset" the wire so that it would expand slightly, filling the gaps between the wires, effectively forge welding the wires together. Once the top of the part (the part with details) is complete, the part could be turned over to each side so that it too could be (welded). Advantages (that I can think of): Low motor strength needed (compared to other CNC machines) Open control scheme, like other repraps Uses a robot that could then be used for normal 3d printing Shapes metal! Disadvantages: Limited part shape (can be overcome with multi-piece parts) Probably pretty loud (compared to a regular 3d printer Manual intervention required mid-print (going from toolhead 1 to toolhead 2) What could you make with such a machine? I think the largest potential would be moulds for other parts. If you were willing to assemble a few parts together then you could probably make quite a few things. https://reprap.org/forum/read.php?178,239899,239899#msg-239899 Mon, 20 Apr 2026 06:03:47 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?178,239899,244938#msg-244938 https://reprap.org/forum/read.php?178,239899,244938#msg-244938 Have you seen those pin blocks, where you put your hand into them and it keeps the shape, I imagine your idea like that, I have seen special vices with an array of adjustable pins to hold awkward items, and I saw a
similar device that has cnc controled pins with a flexible top sheet, it could create sone nice curved shapes.

I should have said pneumatic silencer not filter,]]> johnrpm Delta Machines Thu, 12 Sep 2013 19:25:33 -0400 https://reprap.org/forum/read.php?178,239899,244921#msg-244921 https://reprap.org/forum/read.php?178,239899,244921#msg-244921 dudesom Delta Machines Thu, 12 Sep 2013 17:46:32 -0400 https://reprap.org/forum/read.php?178,239899,244887#msg-244887 https://reprap.org/forum/read.php?178,239899,244887#msg-244887
Sorry to highjack this thread, one day I will try it out.]]> johnrpm Delta Machines Thu, 12 Sep 2013 15:17:56 -0400 https://reprap.org/forum/read.php?178,239899,244800#msg-244800 https://reprap.org/forum/read.php?178,239899,244800#msg-244800 Jeff Thompson's work on voxels. He did some experiments using a CNC to build things out of spheres.

If you could come up with some kind of collet to hold the sphere, you could spin it like crazy and use friction welding. It may not have any advantages over spot welding, but some combination of spinning and zapping might work better than either alone. For example, spinning the sphere might help clean the surface of oxides and other junk at the points of contact, thus resulting in a much higher quality spot weld.]]> MattMoses Delta Machines Thu, 12 Sep 2013 10:54:03 -0400 https://reprap.org/forum/read.php?178,239899,244781#msg-244781 https://reprap.org/forum/read.php?178,239899,244781#msg-244781 johnrpm Delta Machines Thu, 12 Sep 2013 09:25:12 -0400 https://reprap.org/forum/read.php?178,239899,244717#msg-244717 https://reprap.org/forum/read.php?178,239899,244717#msg-244717
Not sure what kind of resolution you'd get, though.]]> Annirak Delta Machines Thu, 12 Sep 2013 06:19:47 -0400 https://reprap.org/forum/read.php?178,239899,244712#msg-244712 https://reprap.org/forum/read.php?178,239899,244712#msg-244712 johnrpm Delta Machines Thu, 12 Sep 2013 06:06:38 -0400 https://reprap.org/forum/read.php?178,239899,244635#msg-244635 https://reprap.org/forum/read.php?178,239899,244635#msg-244635 voxel printing. Though using electrical discharges for welding would certainly be novel.]]> Gene Hacker Delta Machines Wed, 11 Sep 2013 23:16:52 -0400 https://reprap.org/forum/read.php?178,239899,244504#msg-244504 https://reprap.org/forum/read.php?178,239899,244504#msg-244504 this thread a while ago. VDX mentioned some experiments he did with ultrasonic wirebonding and pointed out several difficulties with using the process for freeform fabrication.]]> MattMoses Delta Machines Wed, 11 Sep 2013 13:47:17 -0400 https://reprap.org/forum/read.php?178,239899,244493#msg-244493 https://reprap.org/forum/read.php?178,239899,244493#msg-244493 and have a bank of capacitors, place each ball and zapp weld to the previous ball. infiltrate if needed.

Must get around to building it one day.]]> johnrpm Delta Machines Wed, 11 Sep 2013 13:25:38 -0400 https://reprap.org/forum/read.php?178,239899,243234#msg-243234 https://reprap.org/forum/read.php?178,239899,243234#msg-243234
At the moment I'm thinking about possibly spot welding and alternative robot designs to the Delta type (lathe style polar looks possible). When I get a little time I'll start a new thread someplace I guess.

It's too bad someone's already named their reprap "Blacksmith" :P]]> dudesom Delta Machines Fri, 06 Sep 2013 18:23:57 -0400 https://reprap.org/forum/read.php?178,239899,241949#msg-241949 https://reprap.org/forum/read.php?178,239899,241949#msg-241949
Check out thermosonic welding. It's the process used to bond wires to ICs. Ultrasonic welding is also used to bond plastic cases together.]]> Annirak Delta Machines Mon, 02 Sep 2013 04:12:39 -0400 https://reprap.org/forum/read.php?178,239899,239955#msg-239955 https://reprap.org/forum/read.php?178,239899,239955#msg-239955
I think that for very small wires there would indeed be some flexing issues but, if one used larger gauge wires and a very very small "hammer" (small but fast!) I think it would be worth the (theoretically) increased part durability.

As for adding other fillers, yes that is an awesome idea. This way you get the surface hardness and durability of steel (or whatever). Thanks for your input!

If there are any machinists out there who care to chime in, I'm curious if this small hammer approach could be used to work harden as well, after the initial weld. Would this lead to better material characteristics?]]> dudesom Delta Machines Mon, 26 Aug 2013 15:09:09 -0400 https://reprap.org/forum/read.php?178,239899,239936#msg-239936 https://reprap.org/forum/read.php?178,239899,239936#msg-239936
That is a very imaginative idea, but I believe the wires would flex at every hammer hit. I think that using only the torch woulw be better, only fusing the ends of the wires thogether, but even though, I belive the parts made that way would be very delicate.
Maybe putting the complete part on an oven that fuses all the wires or even better, filling the voids with epoxy or some kind of resin could make some useful parts. It is potentially a new manufacturing method, albeit only useful for some kinds of parts.

By the way, IMHO that could be achieved with any printer, not only Simpson.]]> Guizmo Delta Machines Mon, 26 Aug 2013 14:06:49 -0400 https://reprap.org/forum/read.php?178,239899,239899#msg-239899 https://reprap.org/forum/read.php?178,239899,239899#msg-239899
One tool head equipped with a wire feed (much like a filament feed) and a cutting solenoid. This tool head would push out wire downward into a bed of styrofoam (or other material that would hold the wire) at varying lengths, depending on the topography of the part being printed. Each XY coordinate on the print bed would be handled this way until a "bed of needles" is formed with the rough topography of the part being made.

The second tool would be equipped with a small propane torch and a tiny ballpoint hammer, actuated by a solenoid. After the first tool is done placing each wire, the group of wires would be clamped together. Then the second tool would be used to heat and then hammer the wires downward into the final shape of the part. Each small hammer blow would "upset" the wire so that it would expand slightly, filling the gaps between the wires, effectively forge welding the wires together. Once the top of the part (the part with details) is complete, the part could be turned over to each side so that it too could be (welded).

Advantages (that I can think of):
Low motor strength needed (compared to other CNC machines)
Open control scheme, like other repraps
Uses a robot that could then be used for normal 3d printing
Shapes metal!

Disadvantages:
Limited part shape (can be overcome with multi-piece parts)
Probably pretty loud (compared to a regular 3d printer
Manual intervention required mid-print (going from toolhead 1 to toolhead 2)

What could you make with such a machine? I think the largest potential would be moulds for other parts. If you were willing to assemble a few parts together then you could probably make quite a few things.]]> dudesom Delta Machines Mon, 26 Aug 2013 11:56:42 -0400