From top view,\u00a0it\u00a0looks pretty familiar!<\/p>\n<\/div>\n
Order an\u00a0Onyx sample part<\/a>\u00a0and check out more about the new Markforged material\u00a0here<\/a>!<\/p>\n<\/div>\n
{"id":1583,"date":"2016-07-13T08:31:18","date_gmt":"2016-07-13T08:31:18","guid":{"rendered":"http:\/\/www.mark3d.de\/?p=1583"},"modified":"2017-09-06T19:58:35","modified_gmt":"2017-09-06T19:58:35","slug":"verbesserung-der-dimensionsstabilitaet-mit-dem-onyx-druckmaterial","status":"publish","type":"post","link":"https:\/\/www.mark3d.com\/de\/tipps-zu-technik-und-design\/verbesserung-der-dimensionsstabilitaet-mit-dem-onyx-druckmaterial\/","title":{"rendered":"Verbesserung der Dimensionsstabilit\u00e4t mit dem Onyx Druckmaterial"},"content":{"rendered":"
You may have read from\u00a0our product page<\/a>\u00a0or other Onyx media, like our\u00a0Onyx Intro Blog<\/a>, that the Markforged Onyx filament, available for Mark Two Enterprise 3D printers, has increased dimensional stability and an increased print success rate compared to other 3D printing materials. In this blog I\u2019ll go a bit deeper into why that is and what it means. In this context, dimensional stability refers to the ability of 3D printed components to keep their shape as they are being printed. A printer or material may have poor dimensional stability for a few different reasons. If you\u2019ve worked with FDM 3D printers before, you\u2019ve probably experienced some common issues like part warping as the filament cools, or drooping and poor surface finish beneath unsupported overhangs. Even when support material is used, certain geometries may fail because of the way that filament cools, and as a result parts will either not come out to the spec that you need them to or fail during the print and necessitate redesign.<\/p>\n The micro-carbon reinforced nylon that makes up Onyx filament gives it some of the material properties you may have seen looking at the properties of Onyx listed on\u00a0our data sheet<\/a>\u00a0\u2013 Onyx is stiffer and has different thermal properties, like heat deflection, than most 3D printed plastics. This affects the way it prints \u2013 the stiffness and minimal thermal deformation create much less warping during the 3D printing process. This minimizes peeling off the build plate, allows for more substantial overhangs (both with and without supports), and ensures high dimensional accuracy when 3D printing. Once the filament is extruded, it holds much more true to its form, meaning that your parts are more accurate to your CAD model. As customer Alan Rencher of Media Blackout puts it, \u201cOnyx is a stiffer material, the edges are true\u2026parts look better and they fit together better, so it\u2019s been a huge help. We don\u2019t have to redesign or print new parts.\u201d<\/p>\n To showcase the dimensional stability in 3D printing Onyx, I\u2019ve been trying to push the material\u00a0to its limits and I\u2019ve run a few tests to experiment what Onyx can tolerate. While some of these properties are notably intertwined with our printer, I hope this will give you a good understanding of what we mean when we say \u201chigh dimensional stability.\u201d<\/p>\n Warping is a big problem for many desktop 3D printers, so first I\u2019ll provide a brief explanation of why 3D printed parts warp. Parts warp in the first place because as the printed plastic cools, it shrinks. Once material is extruded, it immediately starts to cool. When the printer traces out the perimeter of a part, it adheres to the build plate. At this point, the material is still cooling, and still wants to shrink, but it is stuck. This creates a force around the perimeter of the part pulling the outsides in \u2013 a thermal moment \u2013 which makes the edge of the part want to curl in toward the center. As another layer is added, it happens again, and the force is now essentially doubled, and this only magnifies as larger layers (layers with more aggressive overhangs) are added, so even with support material parts can fail due to warping. Parts start to peel off the build plate once enough layers have stacked up, which is why you don\u2019t notice it on the first layer. Parts tend to peel up at the corners because they act as stress concentration points. Imagine a single line of filament being laid down. It naturally wants to contract along its length. When two perpendicular lines are introduced, this creates a larger force directly at the corner, as shown in the image below.<\/p>\n Warping occurs at corners because the forces from each edge add up.<\/p>\n<\/div>\n This doesn\u2019t happen as much for round, smooth perimeters because there is no one point in which the force is built up more than another. But it\u2019s still a big problem, so how do you prevent warping in 3D printing? Common solutions to warping vary, including increasing surface area contact at the corners with rafts or discs, heating the build plate, or using a heated enclosure to regulate the cooling more effectively. But really, warping can be solved with materials, too. With stiffer materials that deform less when heat is applied, warping can also be reduced. Onyx is one such material \u2013 its stiffness and its thermal properties mean that it has very minimal warping compared to most other filaments. Additionally, with continuous fiber reinforcement, warping is further reduced because the fiber is strong enough to force the layers to stay flat, thus counteracting the thermal moment with materials instead of external design or printer set-up fixes. We printed a triangular prism balanced on its edge, with 100% infill out of Onyx, as shown in Eiger.io, our slicer:<\/p>\n To test warping, we printed a triangular prism on an edge. The larger layers build up larger forces.<\/p>\n<\/div>\n This shape is really terrible to print because the filament is primarily laid out upon one axis, so it really wants to pull from each side toward the center. That, combined with larger cross-section layers above it (to form the inverted triangle) means that you\u2019re getting a huge force coaxing the part to peel up. Here\u2019s what happened when we printed it out of PLA (100% infill, no raft) on a different FFF (Fused FIlament Fabrication) off-the-shelf desktop 3D printer. The part peeled entirely off the build plate, so it wasn\u2019t actually able to print fully:<\/p>\n The warping test part printed on a PLA based FFF printer with 100% infill. It failed halfway through, and warped pretty significantly.<\/p>\n<\/div>\n And now, here it is out of Onyx:<\/p>\n The part, printed with 100% infill in Onyx. The part finished, and barely warped!<\/p>\n<\/div>\n On desktop 3D printers with single plastic extruders like ours, overhangs are always a big question when it comes to materials, because many people try to design to avoid them. On the Mark Two, this is not always necessary, because our support material ends up being really easy to pull off, as shown:<\/p>\n The support structures our software creates pull right out!<\/p>\n<\/div>\n But even with supports, overhangs are sometimes hard to accomplish for the same reasons that warping is a problem. Larger cross sections stacking on top of smaller ones create a thermal moment that can make the edges of an overhang, even when supported, curl up and jam the printer. With a material like Onyx, there is minimal warping, and thus minimal overhang instability. In fact, it can safely go up to about 70 degrees with no supports, which even we were surprised by:<\/p>\n An overhang test printing out of Onyx on one of our internal R&D Enterprise Printers.<\/p>\n<\/div>\n We used\u00a0Make Magazine\u2019s 3D printing test parts<\/a>\u00a0to evaluate the material. And the surface finish on the underside is still pretty great:<\/p>\n The bottom surface finish of an unsupported overhang, going up to 70 degrees.<\/p>\n<\/div>\n This new filament, combined with our printer\u2019s detailed resolution, mean that you can produce high quality, dimensionally stable 3D printed parts that come out just the way you designed. Take a look at this GIF of us running a negative space tolerance test (also from\u00a0Make Magazine\u2019s test<\/a>), getting down to a 0.2 mm radial gap between each pin and its corresponding hole:<\/p>\n The precision of the Mark Two combined with the material properties of Onyx make for some very stable parts.<\/p>\n<\/div>\n So this is what we mean when we say that our new micro-carbon reinforced Onyx filament has dimensional stability. The part will hold true to its design, meaning that you can use this material to get precise, consistent, and beautiful results, and you won\u2019t need to use any sanding or filler putty to shape your overhangs or flat surfaces to get the quality you need. With Onyx and our engineering desktop 3D printer, you can present end-use parts easily and not have to worry about your 3D printed designs being out of spec. We designed our Part of the Week Award out of Onyx to showcase the kinds of designs it is capable of!<\/p>\n An award we printed for our Part of the Week Winners! The body is Onyx, and the top piece is Nylon<\/p>\n<\/div>\n And from top view, it looks like our logo!<\/p>\n From top view,\u00a0it\u00a0looks pretty familiar!<\/p>\n<\/div>\n Order an\u00a0Onyx sample part<\/a>\u00a0and check out more about the new Markforged material\u00a0here<\/a>!<\/p>\n<\/div>\nWarping<\/h2>\n
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<\/p>\nOverhangs<\/h2>\n
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<\/p>\nDimensional Stability<\/h2>\n
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