3d Printing News — Large Scale 3D Printing - Cosine

Ethan Herrera

Hybrid Manufacturing

Hybrid Manufacturing

Hybrid manufacturing combines the precision and versatility of 3D printing with the power and speed of traditional manufacturing methods. An industrial 3D printer that has both additive and subtractive capabilities is the ultimate example of a hybrid manufacturing solution. With the ability to 3D print an object, then use a subtractive tool such as a milling spindle to remove material, the process enables creating precision complex geometries, but also allows for the creation of features that are difficult or impossible to achieve through 3D printing alone, such as threads or precise dimensional tolerances.

With the ability to switch between additive and subtractive manufacturing, this type of industrial 3D printer offers a wide range of possibilities for creating complex and highly detailed parts and products. From prototyping to end-use production, this technology provides the flexibility and efficiency that manufacturers need to compete in today's rapidly evolving market.

2k Thermoset Technology At Cosine Additive

2k Thermoset Technology At Cosine Additive

Thermoset extrusion technology has revolutionized the way that many industries manufacture and process materials. From automotive parts to construction materials, thermoset extrusion has become a key method for producing high-quality, durable products with precise dimensions and consistent properties. In this blog post, we will explore the basics of thermoset extrusion technology, including how it works, its benefits and drawbacks, and its applications in various industries. We will also discuss the future of thermoset extrusion and how it is expected to shape the manufacturing landscape in the coming years. Whether you are a seasoned professional or new to the field, this blog post will provide you with a comprehensive overview of thermoset extrusion technology and its place in modern manufacturing.

Cosine Tools For All Your Printing Needs

Cosine Tools For All Your Printing Needs

The line up of 3D printing extruders boasts impressive capabilities, offering a range of materials and a high level of precision. These extruders are designed to be plug-and-play, making it easy for users to get started with minimal setup. In addition to their ease of use, these extruders also offer full software control, allowing users to customize and fine-tune their printing processes to achieve the best possible results. Whether you're a seasoned 3D printing professional or a beginner, these extruders provide the versatility and control you need to bring your creations to life.

Automated Pellet Feed Delivery System

The automated pellet material feeding system in this industrial 3D printer makes it easy to continuously print large parts without the need for manual intervention. The closed-loop vacuum system ensures that the pellet material is fed smoothly and consistently into the extruder, resulting in improved print quality and reduced waste. The system is fully automated, allowing users to focus on other tasks while the printer is running. This advanced technology helps to increase productivity and efficiency in the 3D printing process, making it a valuable addition to any industrial setting.

Vacuum Bed Printing Surface

Vacuum Bed Printing Surface

The 3D printing bed on this machine utilizes vacuum pressure to securely hold the build sheet in place during the printing process. This ensures that the print remains stable and produces accurate results. The bed's subassembly is able to reach maximum temperatures of 100 degrees Celsius, making it capable of handling a wide range of materials. This versatility allows for a greater range of printing possibilities, including the use of high temperature materials such as polycarbonate. The vacuum pressure and high temperature capabilities of this 3D printing bed make it a reliable and efficient choice for any 3D printing project.

AM1 Chain Drive vs Belt Drive

A lot of traditional 3D printers utilize a series of belts and motors to produce motion. Consumer grade FFF (Fused Filament Fabrication) printers use belt-driven movement for the X and Y, along with a ball-screw system for the Z axis. We began looking internally for alternatives for our own belt-drive system, and under the same operating conditions, chains were found to be cheaper, easier to order with shorter lead-times, and a lot more compatible hardware that can be found off the shelf. On the AM1 line of machines, the Y bridge is an aluminum billet construction with robust, industrial grade extruder tools. This can add substantial load to the Z axis, which shortens the lifespan of the belt. Also, when compared to chain systems, belt systems require more hardware to install and maintain. 

Cosine Y-Bridge Complete Assembly

Since switching to a chain drive for the Z, we have seen an increase in the lifespan of the system, with significantly less deflection under load. This improves the accuracy of the Z axis during printing and produces more consistent layers throughout prints.  Belts also require periodic maintenance to re-tension the system as the belts plastically deform over time, an issue not seen with belt driven systems.

Although it does not happen often, some belt systems have been known to snap due to an excess of force acting on the Z system, especially when the belts are older and not maintained as well. This cripples the system and translates to a list repairs and maintenance. From in-house testing, the chain system can withstand a much larger amount of stress and force than any belt system of similar size; making it so that the chain system is not a likely point of failure.




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