ultrasonic misting 3d print vapor polisher - polycarb sheets for sale
Steam polishing is nothing new.
Experienced 3D printing enthusiasts are very clear that you can smooth their surfaces by exposing 3D printed objects to the right solvent.
There are some existing methods to do this, but each one has unique shortcomings.
What is needed is a better solvent application method, which is the content of this manual. (
Be sure to check the video at the last step! )
The current steam polishing methods and their shortcomings include: 1.
Heat treatment by boiling solvent in a tank or similar Chamber (
Potentially dangerous and very handson process)2.
Cold treatment by slowly releasing the solvent from a paper towel in a closed container (
Very time consuming, parts cannot be observed during this process. )3.
Spray the canned solvent aerosol onto the part. (
The surface finish is inconsistent and must be done outside)4.
Immerse the part directly in a liquid solvent (
Unpredictable/inconsistent completion, possibly excessive exposure of parts)
All I want is a machine that allows me to quickly put parts into a transparent container and be able to press the "go" key to make the machine itself produce predictable finish.
I don't want to put together a really complicated setup of something that could be a fire, a smoke hazard, or produce an unpredictable surface finish.
Basically, I want something as convenient as a microwave.
I'm also forgetful, so I don't want my parts destroyed if I forget I left the parts in the machine.
Ultrasonic spray 3D steam polishing is the way to solve all these problems.
The key components of this machine come from an ultrasonic humidifier using a piezoelectric sensor (like a speaker)
High frequency mechanical oscillation is produced in liquid.
This vibration forms a very fine drop mist in the fog/fog.
The density of the fog is controlled by the potentiometer changing the strength of the vibration.
This fog is very strong and does not move far by itself, so I use the aquarium air pump to blow it from the fog chamber to the glass finishing room where it can condense on 3D printed parts.
This airflow makes the air move in the finishing room, which helps to produce a consistent finish on the part.
The airflow system is necessary, but we do not want the exhaust gas to be a fume hazard, so there is a blister on the exhaust gas to absorb the excess solvent. (
Please note that this only protects you when using a water-soluble solvent such as acetone. )
If point processing Poland is required, the tube entering the finishing room can be disconnected and pointed manually to the part you want.
This is a good way to use chemicals for solvent welding (
Stick plastic parts together).
Another cool thing about this design is that the fog creation component is separate from the fog application component.
This means that you can do some very precise fog applications using a micro-controller.
In fact, using the simple mechanical timer shown in the figure will still give you a lot of control.
Obviously, you have to be very careful about the solvent.
Read the MSDS table for any chemicals you use and always wear the appropriate PPE when handling them.
Although this machine is designed to be allowed to be used indoors, the only solvent I would suggest to use is acetone.
All other solvents should be treated like poison.
Why is acetone special?
Actually, acetone is something amazing.
Mutual dissolution of acetone and water (they mix well)
So the blister does a great job of removing it from the air.
The absorption volume of water to acetone is about 1 to 1, so keep the water fresh to minimize the smell.
In any case, acetone is completely safe for humans under normal conditions and positive constants.
Believe it or not, the human body has produced a small amount of acetone!
Acetone is the only common solvent other than water that is not classified as VOC or HAP.
This means that there are no regulatory restrictions on this solvent we use.
No other common solvent is so unrestricted!
Acetone is the fastest solvent to evaporate, and one of the strongest solvents in all common solvents, very dry (non-oily).
So it's an excellent cleaner and a skim, and that's how it's used in most industries.
Although it smells bad, you have to consume a lot of this stuff in order to get hurt.
At low concentrations, it's just a stimulus, and all the bad things happen at high concentrations.
Acetone is not considered to be a carcinogenic substance, a mutant chemical, and is not considered a problem with chronic neurotoxic effects.
Cool, so what solvent works best for 3D printed plastic?
ABS: acrylic acetate: most solvents: MEK or "MEK alternative" PVA: water pvc: most solvents-polypropylene: solvent-resistant nylon: solvent-resistant polypropylene: solvent-resistant * before switching to a new solvent, be sure to clean your room.
It's not a joke that a mix of chemicals as common as ketone and alcohol can cause an explosion.
Please refer to the chemical compatibility chart when in doubt: do not "melt" the plastic, but dissolve them.
Melting refers to the physical change of solids to liquids due to the increase in thermal energy.
The reaction here is more similar to what happens when you pour water on the sugar cube. (1)
Air pump and check valve: Aqua Culture 1/2 gallon Betta View with base (
Wal-Mart has the same)(1)
8 "x 6" x 3 "project box: www. radioshack. com/project-enclosure-8x6x3-. . . (1)
Ultrasonic humidifier: Crane Meng ultrasonic cool mist humidifier-Frog(1)
Gas-tight glass jar: a 1-gallon pickle can is perfect. (1)
Brewing gas gate: Make it yourself like I did, or buy a beautiful gas gate here: cylinder gas gate (1)
Empty paint is available at any hardware store: 1 quart or 1 gallon. (3 ft)
1/4 "OD polyethylene tubing: available in any hardware store. (1)
90 degree thread quick disconnect connector for 1/4 OD Tube: available in any hardware store. (3)
Straight thread quick disconnect connector for 1/4 OD Tube: available in any hardware store. Optional:(1)
5-minute spring-loaded mechanical wall timer: Intermatic FD5MW 5-
Note: Some of the parts used in the photos are different from those named here.
I used a project box of 7x5x3 but I think it is too small.
Also, I used a quart paint can, but I think 1 gallon is better because it can hold a whole can of acetone.
Finally, it is essential that your finishing room is not breathable.
For this reason, I don't recommend using the one I got from Wal-Mart (
See in the main photo).
I took her frog humidifier apart and my wife was sad but I insisted on dissecting it for science!
The humidifier is equipped with power cord, power switch, potentiometer, float switch and on/off light.
We will use everything so there is no need to cut off any electronic devices.
All you need to do is take apart the humidifier with a screwdriver.
When everything is separated, all you have to do is trick the floating sensor into thinking it's always on by compressing the float in the up position.
Note: it is better not to operate the vibrator when there is no liquid, I am sure there is a reason why they install this floating switch.
In photo 5, I cut off the power cord of the aquarium air bubble and welded it to the power supply of the humidifier.
This makes the air blister and humidifier powered by the same power cord, and is only turned on when the main power switch is turned on.
If you choose to install the optional 5 minute spring load mechanical wall timer I recommend, then you just need to install it in series with the main power supply, just like a switch.
The installation instructions will be in the timer box.
In this step you can drill holes at the bottom of the paint so you can install the vibrator.
Measure and drill 4 mounting holes and a large through hole of the vibrator itself.
The big hole will be leak-proof due to the rubber seal, but the small hole is more tricky.
The solvent will dissolve most of the glue you use here, so drill your mounting holes as small as possible.
I used two parts of epoxy to help seal it and I didn't notice any leaks.
When you drill holes on the cover of the pipe fittings, be sure to be as small as possible.
You want the fittings to screw in on their own and seal the holes as mechanically as possible, because it is difficult to glue on a large hole if no solvent breaks the glue.
Edit: silicone glue is a great choice for solvent resistance.
It can be noted from the first photo in this instructable that I ran the air bubble tube outside the paint can, not hidden inside.
I did this to avoid having to close another hole at the bottom of the jar.
It's hard to see in the photo, but I added a piece of foam around the air bubble to prevent it from vibrating on the box and making noise.
After you mess up everything inside, you're done!
I will have all the glue dry for 24 hours before inserting any solvent into the chamber.
Before you contact the solvent directly, it is best to test the equipment in the water.
Also, if you bypass the floating switch like I did, then be careful not to turn it on when the machine is empty or something bad may happen.
I am curious about the effect of acetone steam treatment on the mechanical strength of abs samples.
It's a good thing that I happen to have a TestrBot universal test machine to fix this.
The test was very solid, and although the abs samples were given a full 24 hours of drying time, the treatment of abs samples with acetone steam caused them to lose their strength.
For detailed test results, skeptics can check the attached PDF file.
The result is surprising, to say the least.
I expect polishing to strengthen the parts by reducing the surface stress concentration.
My high speculation about the resulting loss of strength is that exposure to the solvent results in permanent chemical changes on the surface of the part, resulting in a softening effect.
Looking at the interior of the part, it is clear that the treatment does not penetrate deep into the place.
Interestingly, the quality of the specimen was measured before and after treatment and before testing.
The quality of specimens increased by about 0.
2 grams after treatment, but weight returned to normal after 24 hours.
To be fair, this is not an exhaustive study.
I tested several samples in one direction.
However, my standard deviation is very low, so my setup is obviously able to produce repeatable results.
With all the factors in mind, having an ultrasonic steam treatment room is still beneficial for anyone who wants to increase the aesthetic value of 3D printed parts.
View video showing the whole process: Update 9-2-
15: I just released a new batch of test results showing how to optimize the strength of the 3D printed parts.