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Too long, didn't read:

Make your own 3D printer filament !
Cheap and high quality at a decent speed of 150-190 IPM ! (4-5 meters per minute)

UPDATE: Now with wiring diagram !

Long read:

3D printers are cool and they finally start to drop in price. Kickstarter campaigns like the one from QB-UP or M3D are popping up and they are finally "affordable". And with affordable I mean affordable like 200 $ and not "affordable" like 2.199$ affordable. However, once you are a proud owner of a 3D printer you will soon realize that your wallet is far from being let alone. No ! You need plastic filament of course to print those super awesome coat hooks and wheel chocks. Since the price for these filaments tend to top the actual material costs, printing before mentioned life savers is kind of expensive and could become a problem to the development of the ever growing 3D printer community

BUT FEAR NO MORE !! Some clever gents came along - Hugh Lyman with his Lyman Extruder may be mentioned here or the guys over at Filastruder.com - and saved the day ! YAY. And there was much rejoicing ! They have built plastic extruders everyone can build or buy at a decent price. However if you are a fellow Instructable.com user the first thing that should come to your mind is "I can build this by myself...and cheaper...". Building at lower costs is the nature of DIY after all.

And much more fun than putting together a premade kit, of course.

Special greetings go out to Xabbax and his plain simple but super awesome Low Cost Filament Extruder !

So how much money do I save when making my own filament ?

Good question ! A lot !

Depending on the pellets you get you can make your filament starting at 1$/kg.

How long does it take to produce 1 kg of filament you may ask ??

Using the build I describe here...roughly 1 hour. (for 1,75mm filament using ABS/PC pellets).

So, let's say on a Saturday in your next workshop session you start at 10 AM and batten down the hatches at 5 PM you could make 4-5 kg of filament, saving between 125-150 $ leaving you with lots of filament for hundreds of thousands of eggcups and phone cases and other useless needful things.

Oh yeah what about the build cost ?

Depending on shipping and local prices, I would guess around 130-150$.

Next step: List of Materials

 
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hamoda15013 days ago

[1] what is the specifications of this wiper motor its volt and torque? and can you give me link of it in online store ?

[2] can i use computer power supply ?

thanks in advance.

SBot_Maker21 days ago

Will this work with PET plastic?

ianmcmill (author)  SBot_Maker20 days ago
Yes, this should work. Just lookup the melting temperature of PET.
swbluto3 months ago

I also found that 16mm was a bit loose for the 3/4inch UNC fitting. The inner diameter of the pipe measures between 19.9-20mm, so a 19mm or 3/4-inch auger bit works best (Tried the 3/4-inch auger at Home depot, a tiny bit loose, but the best fit I could get among the Bosch augers there. Definitely better than the 16mm, or 5/8-inch, auger.)

I went with the 19mm auger bit and a 3/4" pipe as well; however the bit wouldn't fit through the pipe. I'm going to have to go back to the store to either find a bigger pipe or a smaller bit.

ianmcmill (author)  swbluto3 months ago

Yes. Sourcing of specific parts is always a big mess. 'Just' try to get things that fit together. This is what I did. I went into my local hardware store and started to put things together to see if they fit. Then I incorporated it into my build.

All measurements I stated here can basically be exchanged with what you have available. It is not my intention that you have to order simple parts like augers or extenders for big money online. Grab on what you can get your fingers in local stores and adapt them. Just like you did with the water tap extender. This is DIY style.

foul_owl2 months ago

I'm not sure you need the SSR if you have a PID that can switch 250VAC/3A. For example, the REX-C100. Can anyone confirm?

I am using the REX-C100 for my build and I have 110 VAC supplying power to the unit. This PID has a 12 V DC output at pins 4(+) and 5(-). I'm not sure what the amperage will be at the heater band as I haven't turned it on yet (later this week) but I am using the SSR because the heater is 300 watts (from the AC) and I don't think it would be a good idea to try to control that from the PID. Those connections are a bit fragile looking for that much power. A lot safer all around to use the SSR! This unit is made to work with the SSR anyway. Besides, I don't see any AC output from the PID.

Take a look at the datasheet here:

https://www.mpja.com/download/rex-c100.pdf

It says "Relay contact output: 250V AC, 3A" so it looks like it is indeed
specd to handle that much voltage and current. If we are switching a 200
watt heater at 120V AC, that is only 1.7 A, so we are good on both
voltage and current.

Maybe I'm missing something though?

Be sure to check the model ID of the REX c100. Mine is the FK02-V*AN. I cannot find any AC output on that model. Perhaps you have a different model. The "V" in this model is for a SSR only. Maybe the "M" model or the "8" model would work. Check your model numbers carefully! I don't think I would use one without a SSR, it's just easier all the way around!

Hi foul_owl. You could use the internal switching of the PID if it's capacity meets the load. However, if you look at some of the reviews of these PIDs, their external contacts on the back of the unit are screw terminals, but they can have spring-loaded contacts internally. Over time, these contacts can become intermittent, or arc, especially with a full load.. In addition, the circuitry can leave a lot to be desired.. It can be safer to route the full load through a SSR and have a much lower loading on the PIR. If I was using a $100 industrial PIR I would switch the load directly.. I am planning to use a $15 Ebay PIR and I will choose the safer option and use a SSR. I have just finished building a thermostat control with the REX C-100FK02-V*AN, a 25A SSR and a K-series thermocouple. It is controlling a 1500W element very well, with a slight 4 degree C overshoot during initial ramp-up. Hope this helps.

Saidli5 months ago

How can I drill a 1.75 mm hole or smaller? Anyone has an idea?

You can find the drill bits in any size you desire on eBay, and they are relatively inexpensive. I would be first in line to recommend using a drill press rather than a hand held drill motor. You are talking about very thin bits and any movement that isn't straight will bend or snap the bits quickly. And don't be in a hurry!

MaxM15 Saidli3 months ago

With a 1.75 mm drillbit.

Hi thanks for the this instructables, can i use this PID controller http://goo.gl/Ds9XLg and where you buy your pallets?

수유1 month ago

Thanks for your works.

swbluto1 month ago

I'm done creating this and it's producing filament. However, I noticed that occasionally bubbles come out from the extrusion hole causing a "snap", and this creates weakpoints in the filament that easily break apart with the slightest bend. I've installed the melt filter per your specification, but I still seem to get these filament-destroying bubbles. Any ideas?

Random guess: maybe your material is not completely dry and these are steam bubbles. I've read that PLA pellets must be completely dried (even in a dehydrator) before extruding.

Can we use the computer power unit instead of the mentioned power supply? It has a 12V output.

amirloplop2 months ago

can i use PID controller AC version instead of DC 12v?

The AC version has a 12v DC output to the SSR, other than that they are basically the same. It just uses AC for all of its temperature controlling. It does not pass the AC on to the heater band, that is done through the SSR. I base this info on the REX C100 PID.

carroty2 months ago

where can i find pellets that cheap? the only place i've been able to find are online and they kill you with shipping fees

Fragmaster1 year ago
Your list of materials calls for a 200W band heater, but only a 60W power supply. Why is this? What power output is your band heater running at? It must be less than 60W according to your list.
TDWay Fragmaster2 months ago

The power supply unit will only be powering your 12volt controls. It will not be supplying the primary power to the heater. The power to the heater unit comes thru the secondary on the relay, the relay is controlled by the 12v. And is a electromechanical switch that will have 4, 6, or 8 connectors, 2 connections are for 12v DC at about 0.5 - 2 amp the other 4 are pass thru contacts for hi AC voltage that you connect your 110ac to on one side and connect to the heating element on the other side.

BTW the 110v 300w element would work just fine as long as you set the temp correctly, it only the 300w heater unit will just reach operating temp faster.

I only see a 240W power supply.

He edited it to 240W after I brought the 60W typo to his attention.

Doh! Sorry I missed it.

ianmcmill (author)  Fragmaster1 year ago

Oh sorry this is a mistake. The power supply has 240W. Thanks for pointing this out.

TDWay2 months ago

Hi Vlad.

For the size of the heating element it couldn't be anymore than the power draw for a small element on an electric range top, and if properly insulated once it reaches it operating temp that will drop quickly..

Bob 25 2 months ago

Hi, Thanks for this design!

Is it normal that the band heater emit fumes? Thanks.

ianmcmill (author)  Bob 25 2 months ago
You're welcome
ianmcmill (author)  Bob 25 2 months ago
It's possible that it fumes in the beginning but should stop after some time. Maybe there is some grease or oil on the metal that it is wrapped around. However is should not fume constantly.

Maybe some cable insulation is affected ?
Bob 25  ianmcmill2 months ago

Thanks for your reply!

It should be that because the heater is brand new, I wasn't sure! I'll try to heat it a bit longer and check cables. Thanks a lot !

ayyappadasK2 months ago

hello, i want to compound blend nylon and aramid and thus extrude a 3mm filament of the composite . is this possible with your set up ?

Bindie3 months ago

Right now I'm trying ABS, I have recycled old prints, extruded them and cut them to 5-7 mm pellets of about 2 mm diameter. I have tried to print at 190, 210, 235, 245 and after a little while there's bubbling and it looks rough. Is there some solution to this?

I will lower the temperature now and try.

I haven't tried real ABS pellets yet, hopefully though around monday.

I have a 2 mm hole and extrude around 2.5 mm filament.

neodymium3 months ago

Can anyone link to the band heater they used? I'm having a bit of a hard time figuring out which one to get.

Thanks

Would this one do it?

Bindie neodymium3 months ago

That is the one I have, works here.

The Axial ball thrust bearing you have linked returns a lot of bearings of different sizes. I don't want to buy the wrong one, what size should I be looking for?

It depends on the auger bit. You need to match the OD of the shank to the ID of the bearing.

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