carbon-fiber-filament-nozzle-wear

The guys at E3D have published an interesting article with information regarding the wear level of standard brass nozzles used in most FFF/FDM 3D printers nowadays when printing with abrasive filaments. They have made some tests using the ColorFabb XT-CF20 carbon fiber filament printing it with a standard brass nozzle and then with a new hardened steel nozzle that they are now offering as a great solution to working with abrasive 3D printer filaments. It seems that a standard brass nozzle can get pretty worn off after printing just about 250g of ColorFabb XT-CF20 3D printer filament as you can see on the photo above (left is brass nozzle, right is hardened steel nozzle). As a comparison the hardened steel nozzles they are selling do not show any notable wear even after printing 10 times more abrasive filament. So if you are using more exotic filaments that contain more abrasive elements in them, then you should really consider going for a more abrasive resistant nozzle. Unfortunately the hardened steel nozzles being sold by E3D are designed for the extruders that they are also making or other similar models, so if your 3D printer uses a different extruder you should look for alternatives.

The solution to the wear of the nozzle we have found out to work well for the MakerBot Replicator 3D printer that we are using is in the form of specially coated nozzles from a company called AVN Swiss (now apparently renamed to Micro Swiss) and we would recommend to get not only a nozzle, but the thermal barrier tube they sell as well. Earlier this month we have tested the same ColorFabb XT-CF20 carbon fiber filament that E3D used and after printing about 200 grams of it with the specially coated nozzle from AVN Swiss we did not notice any wear on the nozzle and we have used it with other abrasive filaments prior to that. So MakerBot Replicator 2 and other MakerBot users as well as ones that have a clone 3D printer to check these upgrade nozzles or even better the whole hotend upgrade.

For more information about the nozzle wear tests with abrasive filament performed by E3D…

coffeekit-proto-pasta

The filament maker Proto Pasta has released new version of their High Temperature PLA filament that looks very promising for anyone looking to work with PLA filament, but get much higher resistance to high temperatures that could be similar or even better than that of ABS. Earlier this yeat we have tested the original Proto-Pasta High Temperature PLA Filament and it did quite well, but it offered heat deflection of up to 88°C and the new version of the filament promises up to 140C. The print parameters are apparently similar to that of standard PLA filament, but with the High Temperature PLA you will need to heat threat the 3D printed part after it is ready.

Proto Pasta have used an oven at 110C for about 30 minutes with good results and they do recommend leaving the supports on your parts, placing them on a non-radiating surface (like glass, ceramic, or composite), and letting them cool in the oven to minimize distortion. Parts can be annealed at a lower temperature (though must be above 60C) for a longer time with less risk of unwanted deformation. There is an obvious visual change indicating the improved performance of the filament.

The new Proto Pasta High Temp PLA v2.0 is available in two variations – standard with Iridescent Ice or Silver Smoke color as well as a special limited edition Aromatic Coffee PLA. Both are available in 1.75 and 2.85 (3) mm diameter and come on 500 gram spools with a price of $35 USD at the moment. The Aromatic Coffee PLA comes with a nice pearlescent, translucent bronze color when printed and becomes very wood-like when annealed and releases an invigorating roast coffee scent when heated.

colorfabb-xt-cf20

ColorFabb XT-CF20 is a copolyester based carbon fiber composite material that is based on the Amphora 3D polymer from Eastman Chemical and is loaded with no less than 20% specially sourced carbon fibers suitable for 3D Printing. The XT-CF20 filament uses the XT-Copolyester instead of the PLA/PHA from COlorFabb and the result is a filament with higher strength and toughness as well as resistance to higher temperatures before starting to get soft. The not so good thing compared to PLA/PHA is that a heated build plate is recommended for using the XT-Copolyester for your prints to stick better, although you could end up getting good results on 3D printers without a HBP as well. The combination of XT-Copolyester with 20% of carbon fibers in the ColorFabb XT-CF20 is very good and prints using this filament, we have previously tested carbon fiber-based filaments with PLA such as Proto Pasta’s Carbon Fiber PLA, but the XT-CF20 does seem to do better job.

The XT-CF20 does seem to be less brittle and a bit more stiffer with a better resistance to higher temperatures thanks to the 80 degrees Celsius glass transition temperature. The carbon fiber-based solution from ColorFabb also does seem to contain a bit more carbon fibers – 20% as opposed to just 15% in the Carbon Fiber PLA that we have previously tested. ColorFabb XT-CF20 does require higher printing temperature with 240-260C recommended, it is recommended to be printed using 40-70 mm/s speed and a heated build plate (if available) is recommended at 60-70C. Also do note that carbon fiber filament is more abrasive than standard filament, so it can shorten the life of standard brass nozzles by increasing the wear level. So it is recommended to use a printing nozzle with some sort of coating such as the ones we have tested from Performance 3-d or AVN Swiss.

colorfabb-xt-cf20-2

We have tested printing with the ColorFabb XT-CF20 carbon fiber filament on our trustworthy MakerBot Replicator 2 3D printer with some useful upgrades such as a coated nozzle and added HBP, so we had not trouble or worries using the XT-CF20 filament. The first test was to try and print using the carbon fiber filament on a cold build plate, we’ve already had some experience using the XT-Copolyerster filament using the ColorFabb XT Transparent Filament earlier this year before upgrading the 3D printer with a heated build platform. Interestingly enough the XT-CF20 carbon fiber filament does seem to print easier and to stick better than the XT transparent filament probably due to the carbon fibers. All we’ve had to do was to enable the use of rafts and we got a great quality print on our first try at 240 degrees Celsius printing temperature and going to 260C did not make much difference. We were able to print smaller parts at 90 mm/s printing speed at 0.2 mm layer height without any trouble, though you would probably want to reduce the speed a bit for finer details. Also no trobule removing the raft from the actual model and getting a good quality base of the part that was 3D printer on the raft.

colorfabb-xt-cf20-3

Next was to test the ColorFabb XT-CF20 carbon fiber filament using the heated build plate at the recommended settings and see how things will go without having to use a raft when printing. We have started with 240C extruder temperature and tried with both 60C and 70C temperature of the HBP, but with both we’ve had trouble with the base of the 3D printer part to stick properly on the build plate. Moving to 250 degrees Celsius for the extruder we had the part sticking better and remaining on the build plate, but the base of printer part has shown that it still did not stick perfectly at either 60C or 70C HBP temperature. Going to 260C for the extruder and we got the filament sticking well at either 60-70C temperature for the heated build plate. The only problem that remains and that is associated with the high extrusion temperature is that the filament oozes from the nozzle a bit more when the printing head moves over longer distances to continue printing for larger objects. Other than that, with the right settings the ColorFabb XT-CF20 carbon fiber filament does seem quite easy to work with and provides good results, now we only need to print some parts that would be stress tested like something for an RC model.

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