Development and Implementation of a High-Temperature FDM Machine for Additive Manufacturing of Thermoplastics

In recent years, the reduction in the entry cost of additive manufacturing has allowed for a paradigm shift in research and development methodologies worldwide. Explicitly focusing on FDM-based manufacturing and its role in the e-design process, this technology has dramatically reduced the idea to market timeframe compared to traditional manufacturing. However, the most significant drawback to this change is that these technologies are currently limited to low load and thermally static applications based on the material capabilities of many FDM machines. The exception to this rule is the few machines capable of printing with materials such as ULTEM and PEEK with thermally controlled chambers to address the above problems. Unfortunately, these machines are generally out of reach for most due to their cost and proprietary materials and software. This paper will outline the development and construction of a printer capable of working with materials at 500 degrees centigrade by utilizing a water-cooled dual extrusion system. This system will be operating inside a closed chamber capable of holding temperatures constant at 100 degrees centigrade. The entire system was manufactured for only 4% of the cost of current market offerings. The printer is based on a market available platform that has been upgraded to include a direct drive water-cooled dual extrusion head. The chamber heating is handled by a 110-volt platform that pairs with secondary heaters to control the interior temperature. The entire motion system is enclosed to control thermal swings, and all electronics are exterior mounted and cloud-based for monitoring and operation. In addition, this printer allows the fabrication of designs that produce parts that are up to six times stronger, three times more heat resilient, and three times less water absorbent. The reduction in entry cost to work with engineering-grade thermoplastics will significantly increase the adoption rate of additive manufacturing in small businesses and design shops.