Reprap Forum - MetalicaRap A self-replicating metal powder printer: http://reprap.org/wiki/MetalicaRap https://reprap.org/forum/list.php?215 Fri, 13 Mar 2026 16:56:21 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?215,888053,888066#msg-888066 Re: 3D Metal Printer Project - Electron beam melting https://reprap.org/forum/read.php?215,888053,888066#msg-888066
The same with a flat surface ... but here this random displacement is not so big, as with a gap (or concave surface) ...]]> VDX MetalicaRap Tue, 25 Jan 2022 08:58:12 -0500 https://reprap.org/forum/read.php?215,888053,888065#msg-888065 Re: 3D Metal Printer Project - Electron beam melting https://reprap.org/forum/read.php?215,888053,888065#msg-888065 I think you mean about the focus spot size?. When the focus size is big, you will have a gradient and the heat is not applied efficiently in the spot.
In the case of electron beam, you can control the focus size.
Regards!]]> chucrutcito MetalicaRap Tue, 25 Jan 2022 08:26:16 -0500 https://reprap.org/forum/read.php?215,888053,888064#msg-888064 Re: 3D Metal Printer Project - Electron beam melting https://reprap.org/forum/read.php?215,888053,888064#msg-888064
... I've already seen the video in your project-link.

It seems to be different, if the beam-"target" is a flat surface, a bulge (convex) or a "concave" structure between two parts -- while the laser simply "points" to a spot, the electron beam deflects with varying flux gradients ...]]> VDX MetalicaRap Tue, 25 Jan 2022 08:16:06 -0500 https://reprap.org/forum/read.php?215,888053,888062#msg-888062 Re: 3D Metal Printer Project - Electron beam melting https://reprap.org/forum/read.php?215,888053,888062#msg-888062 I dont have experience welding Kovar and Inconell yet. Maybe is more difficult. I can test later.
I have welded stainless steel with the electron beam and I find it relatively simple to position the electron beam in welding applications.
I have uploaded this video for showing the electron gun testing:
[www.youtube.com]

I can upload more videos later. You can assign a trajectory to the beam (spiral, sawtooth, etc), so you have precise control of the heat input :)]]> chucrutcito MetalicaRap Tue, 25 Jan 2022 07:43:10 -0500 https://reprap.org/forum/read.php?215,888053,888061#msg-888061 Re: 3D Metal Printer Project - Electron beam melting https://reprap.org/forum/read.php?215,888053,888061#msg-888061
So I'm more the "laser type" B)-]]> VDX MetalicaRap Tue, 25 Jan 2022 07:30:12 -0500 https://reprap.org/forum/read.php?215,888053,888058#msg-888058 Re: 3D Metal Printer Project - Electron beam melting https://reprap.org/forum/read.php?215,888053,888058#msg-888058 The price estimation is around 6.000USD for this 3D Metal Printer if you make it yourself, using the final design.
The research & development is more expensive. If you support me with the development, i can continue working fulltime in this project and publish the designs, schematics, tests, etc.
The advantage of using an electron beam, is the faster XY speed using coils. Electrons have no inertia (almost), so you can move them very fast!

Also when you print a 3D Metal part with laser is very important to take in account heat deformation and cracks when the piece cools itself. If you need a durable and strong part, you will also need an oven to heat the metal part and slowly cool it to eliminate internal stress.
With electron beam printing you dont need an additional oven. The electron beam can be defocus to pre-heat the powder, so you focus again to start the sintering process according to your design.]]> chucrutcito MetalicaRap Tue, 25 Jan 2022 07:11:50 -0500 https://reprap.org/forum/read.php?215,888053,888056#msg-888056 Re: 3D Metal Printer Project - Electron beam melting https://reprap.org/forum/read.php?215,888053,888056#msg-888056
good luck with your project! :)-D

What's the price-tag with the electron gun?

I'm actually more with high-power 200W-IR-laserdiodes, salvaged out from broken/dismanteled muti-kW-fiberlasers, which can be bought at ebay for 500€ (bought several two years ago for 300€ each).

They can be focussed on 0.3mm with a 50mm-FL-lens and only needs 12V with up to 40A and "only" shielding gas, no vacuum.

Plans to use them in combination with CW-fiberlasers (0.02mm spot diameter) for the "finer" details ... and other wavelengths diode lasers (blue 40W @450nm and red 652nm @20W) to reduce the reflectivity of the surface or "optimize" the power absorption B)]]> VDX MetalicaRap Tue, 25 Jan 2022 06:55:50 -0500 https://reprap.org/forum/read.php?215,888053,888053#msg-888053 3D Metal Printer Project - Electron beam melting https://reprap.org/forum/read.php?215,888053,888053#msg-888053 My name is Agustin. I'm from Chile. I have been reading and following MetalicaRap for many years, and I would like to share with you my creation.
I'm making a 3D Metal Printer using an electron beam. Is a very expensive project, and I have worked many years on it.
Now I'm opening the project to the community inside a crowdfunding model. I'm going to share the design, tests, updates, so I can receive some support and continue working 100% in this project.
Recently I made a Patreon page for this purpose:
https://www.patreon.com/3dmetalprinter

I'm wondering if you can take a look to this project. I can share with you pictures, and all the information you need.
My goal is continue working fulltime in this project, so any support is welcome!. Many thanks!]]> chucrutcito MetalicaRap Tue, 25 Jan 2022 05:48:24 -0500 https://reprap.org/forum/read.php?215,826939,886139#msg-886139 Re: Another active project - electron beam welder/3D printer https://reprap.org/forum/read.php?215,826939,886139#msg-886139 Athamanatha Kitsune MetalicaRap Sun, 19 Sep 2021 11:47:44 -0400 https://reprap.org/forum/read.php?215,666224,886138#msg-886138 Re: Copenhagen Progress https://reprap.org/forum/read.php?215,666224,886138#msg-886138 Athamanatha Kitsune MetalicaRap Sun, 19 Sep 2021 11:10:31 -0400 https://reprap.org/forum/read.php?215,826939,883836#msg-883836 Re: Another active project - electron beam welder/3D printer https://reprap.org/forum/read.php?215,826939,883836#msg-883836 hyna MetalicaRap Wed, 05 May 2021 04:41:10 -0400 https://reprap.org/forum/read.php?215,666224,845139#msg-845139 Re: Copenhagen Progress https://reprap.org/forum/read.php?215,666224,845139#msg-845139 Link to ferite core above has changed full details below to get elsewhere when needed.
Material CF139
Equivalent to
manufacturer / material
Cosmo / CF138,
Ferroxcube / 3C90
TDK / PC44
Dimensions U126x91x20
(U shape , base of U 126mm, verticals of U 91mm, square section 20mm x 20mm)

U126x91x20 CF139
Part code
6744 01
Ferrite U core. Manufacturer: Cosmo Ferrite Material Grade CF139 (Equivalent to Cosmo CF138, Ferroxcube 3C90 and TDK PC44). Price is for a half core - (I.e. you will need to order 2 pieces to form a pair) Dimensions: Length: 126mm Width: 20.0mm Height: 91.0mm Wt: 700g Magnetic Characteristics: uiac = 2100 AL Value = 2800 (+30% /-20% For larger volume enquiries or technical assistance please contact our sales team. Tel: 01280 817243 or email: sales@powermagnetics.co.uk Contact Us

Kind regards
Tansen]]> rapatan MetalicaRap Tue, 22 Jan 2019 14:12:05 -0500 https://reprap.org/forum/read.php?215,831217,832605#msg-832605 Re: Managed versionable repository https://reprap.org/forum/read.php?215,831217,832605#msg-832605 We have decided to use GitLab
As they support tools for moving our data later if necessary.
Also support continual software integration,
Also NASA uses it.
But if you could help setting it up on gitlab that would be great.
Kind regards
Rapatan

My user name is rapatan

Project name MetalicaRap]]> rapatan MetalicaRap Sat, 01 Sep 2018 15:36:43 -0400 https://reprap.org/forum/read.php?215,831217,831217#msg-831217 Managed versionable repository https://reprap.org/forum/read.php?215,831217,831217#msg-831217
happy to learn about MetalicaRap!

Also I have to admit it is not easy to get an overview of digital artefacts created in the projects.

What do you think if MetalicaRap could have a GitHub based organization with a set of (or even just one) repositories organized for example like the following:

- hardware
-- module1
-- module2
- software
-- module1
-- module2
- management
-- BOM
-- project plans
- documentation
-- user manual (could be a TeX project)
-- possibly copies of sourced parts documentation if applicable

At GitHub, not only versioning is possible but also:

- release and distribution of file releases
- automation of for example manual generation or software compilation and testing
- issue and task management and tracking

What do you think? if we would agree on the first structure I'd volunteer to pick up existing files, set up the repository and add accounts.]]> reprap80 MetalicaRap Tue, 14 Aug 2018 12:48:35 -0400 https://reprap.org/forum/read.php?215,666224,828399#msg-828399 Re: Copenhagen Progress https://reprap.org/forum/read.php?215,666224,828399#msg-828399 This is the template file for laser cutting the mica sheet inter 3-wind pcb’s insulators referred to above;

[drive.google.com]

Kind regards
Rapatan]]> rapatan MetalicaRap Thu, 12 Jul 2018 07:08:52 -0400 https://reprap.org/forum/read.php?215,826939,827881#msg-827881 Re: Another active project - electron beam welder/3D printer https://reprap.org/forum/read.php?215,826939,827881#msg-827881 Looks Great!
Now we got some competition!
Excellent
Kind regards
Rapatan]]> rapatan MetalicaRap Thu, 05 Jul 2018 20:04:33 -0400 https://reprap.org/forum/read.php?215,666224,827880#msg-827880 Re: Copenhagen Progress https://reprap.org/forum/read.php?215,666224,827880#msg-827880

This is the transformer for 250khz to 500khz LCC 60KV full bridge SMPS resonant converter we are playing with;

[drive.google.com]

[drive.google.com]

[drive.google.com]

[drive.google.com]

[drive.google.com]

[drive.google.com]



Quote number (below) in white in picture on pcb at [jlcpcb.com]
Picture here ;[drive.google.com]
We ordered 100 pcb’s making 200 individual 3 wind boards you need 151 of these individual 3 wind boards.

The plastic parts are in parts section 9 on reprap.org/wiki/Metalicarap. Print in abs solid
[reprap.org]
[reprap.org]

Capacitors
[eu.mouser.com]

Diodes
[eu.mouser.com]

Two of above diodes and two capacitors for each individual 3 wind boards. The two different boards marked CW and ACW respectively should alternated up stack( CW=Clockwise ACW=anti-clockwise, used to reduce parasitic capacitance between winds ) Capacitors one side and diodes other side as marked. Mica sheet(below) between each 3 turn wind board, with protrusion covering the diodes. Then inter 3 turn wind board connection using end copper tabs with a small or large hole in, align these holes over each other,then make connection via soldered small hole through to larger hole above.


Mica sheets 6 packs Mica film 0.2mm Mica Electrical Insulating Film, 304mm x 200mm x 0.25mm [export.rsdelivers.com]


.pdf file of mica insulation sheets laser cut shape file TBA


Ferite Core U126x91x20CF139. [powermagnetics.co.uk] Need two


Big welcome to hyna electron gun development; [hackaday.io]

Kind regards

Rapatan

Be safe out there!
NB you should consider these as not tested.
NB neither metalicarap team or any individual involved in this endevour make any warranty, express or implied, or assumes any legal liability for the accuracy, completeness, or usefulness of any information herein, or represents that its use would not infringe privately owned rights; or assumes any liability with respect to the use of, or for damages resulting from the use of any information, method or process disclosed in this publication.]]> rapatan MetalicaRap Thu, 05 Jul 2018 19:28:47 -0400 https://reprap.org/forum/read.php?215,826939,826939#msg-826939 Another active project - electron beam welder/3D printer https://reprap.org/forum/read.php?215,826939,826939#msg-826939 I´m not a part of MetalicaRap team, but i´m doing the same by my own.
If you are interested in my progress, check this link:
https://hackaday.io/project/54658-metal-3d-printer-electron-gun

Hynek]]> hyna MetalicaRap Tue, 26 Jun 2018 03:40:31 -0400 https://reprap.org/forum/read.php?215,764143,777464#msg-777464 Re: Is this project still active? https://reprap.org/forum/read.php?215,764143,777464#msg-777464
So far though the project sound awesome, I look forward to being able to print mechanical parts one day :D.]]> Crigon MetalicaRap Mon, 10 Jul 2017 19:03:26 -0400 https://reprap.org/forum/read.php?215,764143,775489#msg-775489 Re: Is this project still active? https://reprap.org/forum/read.php?215,764143,775489#msg-775489
I would be keen to put one together if the design is good.

My lab psu died recently :(


And the new coils. does that mean you've fired some up?

I'm half keen on putting together the gun layout you have, its nice with the coils on the outside. Would you recommend it as is? or should I do some math on it to double check what's happening?]]> pyrotronics MetalicaRap Thu, 29 Jun 2017 06:12:30 -0400 https://reprap.org/forum/read.php?215,764143,774504#msg-774504 Re: Is this project still active? https://reprap.org/forum/read.php?215,764143,774504#msg-774504
We have added some more flanges to the electron gun. So you can build the gun sections.


In file and parts section new assemble "assemble301.zip"
Notes for the above,
Modular design implemented through multiple flange connection in gun, Magnetic Lens 1 and Lens 2 are now designed for ease of manufacturer (Part numbers for lenses is coming in next upload) available when .stp file is unziped and opened in FreeCAD. NOW READY FOR BUILDING - using standard part for cross c-0600-450 Lesker

Powersupply development going well , manufacturing of parts continues.

kind regards
Metalicarap team]]> rapatan MetalicaRap Fri, 23 Jun 2017 06:05:40 -0400 https://reprap.org/forum/read.php?215,666224,774503#msg-774503 Re: Copenhagen Progress https://reprap.org/forum/read.php?215,666224,774503#msg-774503
We have added some more flanges to the electron gun. So you can build the gun sections.


In file and parts section new assemble "assemble301.zip"
Notes for the above,
Modular design implemented through multiple flange connection in gun, Magnetic Lens 1 and Lens 2 are now designed for ease of manufacturer (Part numbers for lenses is coming in next upload) available when .stp file is unziped and opened in FreeCAD. NOW READY FOR BUILDING - using standard part for cross c-0600-450 Lesker

Powersupply development going well , manufacturing of parts continues.

kind regards
Metalicarap team]]> rapatan MetalicaRap Fri, 23 Jun 2017 06:03:39 -0400 https://reprap.org/forum/read.php?215,764143,768448#msg-768448 Re: Is this project still active? https://reprap.org/forum/read.php?215,764143,768448#msg-768448 alan8325 MetalicaRap Tue, 16 May 2017 18:31:08 -0400 https://reprap.org/forum/read.php?215,764143,768357#msg-768357 Re: Is this project still active? https://reprap.org/forum/read.php?215,764143,768357#msg-768357 Still making parts for electron gun, new design of coils soon. Still testing power supply.
Good idea to start US group.

Kind regards
Rapatan]]> rapatan MetalicaRap Tue, 16 May 2017 11:17:04 -0400 https://reprap.org/forum/read.php?215,192211,765619#msg-765619 Re: Microwave sintering https://reprap.org/forum/read.php?215,192211,765619#msg-765619 MechaBits MetalicaRap Tue, 02 May 2017 23:10:42 -0400 https://reprap.org/forum/read.php?215,192211,765395#msg-765395 Re: Microwave sintering https://reprap.org/forum/read.php?215,192211,765395#msg-765395
Read this part:

Quote

The plastic is loaded with 60% metal powder and a two-part plastic system.
The primary plastic binder is then dissolved out of the part.
This creates a 20% reduction in material, and turns the part into a sponge.
Next you put it into a sintering oven.
The oven burns off the remaining 20% plastic through the sponge structure (in an environment tuned for the metal) and then brings the part very close to the melting temp.
There are four methods of mass transports, but the net effect is that the atoms diffuse together (sinter), the part shrinks by 20%, and you get a fully dense part (in casting terms, this is 98% or more).

You'll get around 20% percents shrinkage of the parts ... and even this percentage is not accurate, but can vary some percents up or down.

For design parts this won't be problematic - simply design the object bigger ... but what, if you need construction- or dimensional accurate replacement parts :S

Comercial manufacturers solve this by CNC-milling the solidified parts to the accurate end dimensions ...]]> VDX MetalicaRap Tue, 02 May 2017 02:58:50 -0400 https://reprap.org/forum/read.php?215,192211,765361#msg-765361 Re: Microwave sintering https://reprap.org/forum/read.php?215,192211,765361#msg-765361 techcrunch.com]]]> MechaBits MetalicaRap Mon, 01 May 2017 19:33:02 -0400 https://reprap.org/forum/read.php?215,192211,765359#msg-765359 Re: Microwave sintering https://reprap.org/forum/read.php?215,192211,765359#msg-765359 [shop.thevirtualfoundry.com]
They say it is possible to sinter to solid metal using a klin.
Why not using a microwave klin? There are on the market mani available for glass. And they are pretty cheap. Anybody tried?]]> violator83 MetalicaRap Mon, 01 May 2017 19:21:04 -0400 https://reprap.org/forum/read.php?215,764143,764148#msg-764148 Re: Is this project still active? https://reprap.org/forum/read.php?215,764143,764148#msg-764148 VDX MetalicaRap Mon, 24 Apr 2017 18:04:12 -0400 https://reprap.org/forum/read.php?215,764143,764143#msg-764143 Is this project still active? https://reprap.org/forum/read.php?215,764143,764143#msg-764143 alan8325 MetalicaRap Mon, 24 Apr 2017 17:00:47 -0400