3D Printing Providence leader Matt Stultz gives the lowdown on a variety of some of the new and exciting advanced 3D printing materials and their uses. The range of filaments covered includes: thermochromic, conductive, Laywood, Laybrick, HIPS, nylon, and TGlass.

SkyDelta is a new style of open-source RepRap 3D printer. Similar to deltabots like the Kossel, Rostock, Cerberus, Wolfstock, and many others, it has a triangular-prism frame. However, instead of using linear rails and rigid rods to move the print head through space, SkyDelta employs tensioned lines.

Today the Computer Vision and Geometry Lab of the Swiss Federal Institute of Technology (ETH Zurich, Switzerland) announced on December 3, 2013 recent research results turning a normal smartphone into a mobile 3D scanner. 3D scanning aims to capture the geometry of the 3D world, however most existing solutions require a complicated setup, are often hard to use and might not always work outdoors. The technology was demonstrated publicly for the first time today at the International Conference on Computer Vision in Sydney, Australia.
Instead of taking a normal photograph, a user simply moves the phone around the object of interest and after a few motions, a 3D model appears on the screen. As the user keeps moving, additional images are recorded automatically and used to extend the 3D model. As all calculations are performed directly on the phone, the user gets immediate feedback and can select additional viewpoints to cover missing parts of the 3D model. This is an important advantage compared to solutions that batch process all the images in the cloud at a later time.

The app also makes it possible to visualize the state of the 3D scan from different viewing angles, allowing the user to cover all the areas of the object he is interested in. Having a solution on a mobile phone enables the acquisition of 3D scans on-the-fly anywhere. Our approach works in a wide variety of settings, including low-light conditions such as inside a museum. A user can capture a 3D model of a museum piece and interactively study it at home later. After reviewing the model, a user might decide to upload his 3D data to a cloud service to further refine the results.

By using the inertial sensors of the phone, the scanning process can be made simple, intuitive and robust. After the 3D capture is started, the system automatically determines the correct moments to extract camera images based on the user motion.
Contrary to image-only 3D capture solutions the app is able to determine the absolute size of the scanned 3D object, as well as the vertical direction. Because of the complexity of the calculations needed to reconstruct hundreds of thousands of points, the graphics co-processor (GPU) of the phone is used to enable a faster reconstruction and increase interactivity for the user.

The technology also allows the 3D capture of faces, giving a third dimension to portraits, profile pictures or images of loved ones.
Having a convenient way of getting 3D models of everyday objects, users will now be able to copy real-world objects by scanning a full 360 degree model of an object. The resulting 3D model can be used for visualization or augmented reality applications, or even be used for 3D printing, potentially at a remote location, effectively enabling the user to replicate an object.
The patent pending technology was developed exclusively by ETH Zurich and can run on a wide range of current smartphones.

• Reduced leak/failure points with only one conjunction
• Heavyweight that is lightweight: 29g making it the lightest all-metal universal hot-end
• Compact size – including nozzle: 56mm x 14.3mm dia. making it the smallest footprint of all-metal universal hot-ends
• High strength and durable
• Meltdown-free, long-lasting, plastic-free design
• Built-in 13mm wrench flats
• High-efficiency integrated vertical heater block. Threads inhibit heat transfer in threaded heater blocks
• Precision machined with tolerances meeting aerospace grade
• Precision-machined 45 degree chamfered nozzles for a leak-resistant compression fit
• No Kapton tape
• choice of nozzle size: .35, .4, .5, or .6mm

• US made heaters replace sub-par imported heater cartridges
• 40 Watts, 12 volts or 24 volts
• High-temperature 25in DuraFlex® leads
• 6.23mm diameter (¼in) (+/- 0.04mm) by 20mm long

Vicknes Waran from the University of Malaya in Kuala Lumpur, Malaysia, and colleagues created the model using the latest generation of 3D printers, which can print plastic in a variety of textures, from rubbery to hard. By tweaking the printer's settings, they mimicked the consistency of skin, bone and membranes to build up the layers inside a skull. To reproduce a jelly-like tumour, plastic was injected into an anatomically accurate cavity created by the printer, based on scans from a patient. It was then coloured red to add realism.
The skull is an improvement over existing models that use a single material because it allows trainees to see, feel and even hear how each type of tissue responds. Patient-specific replicas can simulate different medical conditions, allowing students to rehearse an entire operation ahead of time.
The researchers also made models of the head. These can be reused, but the model brains with internal structure are custom-made for each practice session. Each costs about $600 to make, which makes it an affordable option.
The team has already created even more sophisticated model brains with cavities that students can probe. "It bleeds and has fluid for brain endoscopy," says Waran.

Proto Pasta offers:

Carbon Fiber Reinforced PLA

Proto-Pasta High Temperature PLA is made from a custom compound consisting of mineral filled impact modified PLA with a nucleating agent to help promote crystallization. Crystallization after printing is what gives this material added heat resistance. To fully realize this advantage, parts must be soaked in hot water or an oven after printing at 60C-80C for 3-5 minutes. This crystallizes the material and makes it much more heat resistant. It does not require a heated bed to print well, but this may help crystallize the material after printing and make oven soaking unnecessary for some parts. High Temperature PLA is a glossy off white, or very light gray. Printed parts look good and have slightly more texture than standard PLA. This material is not translucent like standard PLA.
We have had good results printing at 190C-210C using a .5mm nozzle and direct-drive spring loaded pinch-roll style extrusion head.
Layer adhesion is good and the material has low warpage.

Polycarbonate/ABS Alloy

Proto-Pasta Polycarbonate-ABS (PC-ABS) Alloy is an incredibly tough material designed for strong, resilient parts. When printed, PC-ABS is bright glossy white.
Proto-Pasta PC-ABS Alloy can print well. It is very moisture sensitive and even if stored bagged with desiccant, drying in an oven for ~ 1hr at 85C-95C may be required for bubble free high strength prints. Layer adhesion can be an issue if the part is large or the temperature is too low. We have had good success printing parts ~60mm long at 260C-280C using a .5mm nozzle and direct-drive spring loaded pinch-roll style extrusion head. A heated bed may help warpage and layer adhesion on larger/thicker parts.

Proto Pasta filament properties

They also offer Reusable filament Folding Spool

http://www.proto-pasta.com/

• Flexible Strength
• 100% Recyclable
• FDA Approved for contact with foods
• Easy Adhesion (No heated bed required. Sticks to blue painters tape)
• Hydrophobic: Doesn't absorb water like nylon does
• High qualify spooling and extrusion. Consistent diameter and no bubbles
• More flame resistant than PLA and ABS
• PET+ is compatible with 3D printers that use 1.75mm size filament.
• Price: $34.99 for 1 lbs / 0.45kg and $69.99 for 2.2lbs / 1kg. 
• Available in translucent Clear and in opaque Black, White, Green, and Red.
• PET+ is stronger than many ABS filaments and has the high print success rate of PLA. It is ideal for functional objects that need to combine toughness with flexibility, such as phone cases, wearables, robotics, and mechanical parts.

This time I tested several different plastic types and varying strength Sodium Hydroxide.
1.0 Molar: 40g per liter water
1.8 Molar: 72g per liter water (same as the video)
3 Molar: 120g per liter water
6 Molar: 240g per liter water

Test Result:
After 5 hours in the ultrasonic tank @ 60°C there was no visual effect or surface hardness change evaluating the samples under a microscope of the different plastic types except the PLA.

There are generally two types of thermoplastic that are available for filament type 3D printers, ABS and PLA plastics. These filaments are available in many colors and diameter sizes of 1.75mm & 3mm (0.070 & 0.118 inch). Currently these are pretty much the only sizes that can be used in these 3D printing machines. There are other types of thermoplastic available today that are available as an extruded filament however these have larger cross-sectional diameters of 0.125, 0.156 & 0.188 (3.18mm, 3.96mm and 4.76mm). These are sold as plastic welding rod and are typically used for joining sheets of plastic together. These larger diameter filaments come in many different types of plastic that have for the most part not been used by the 3D printing community. Many types of plastic welding rod are considerably less expensive per pound than the common printer filament of ABS and PLA. So if this material could be made to work in a plastic printer you could have a greater variety of plastics for printing and lower material cost. Our solution is to create a new extruder that can be fitted to existing 3D printers to enable these printers to use all of these different diameters of filament and handle the wider range of processing temperatures for the different thermoplastics.
We have already built 3 versions of our NEMA 23 extruder so far with improvements being incorporated to each new version. We have run the extruders with various materials and are convinced we have a good product here. Our plan is to manufacture our extruders in two sizes. A large extruder driven by a NEMA 23 stepper motor and a smaller version driven by a NEMA 17 stepper motor. The larger version will be able to run all of the filament sizes from 1.75mm to 4.76mm (0.070 to 0.188 inch). The smaller version will run filament sizes 1.75mm to 3mm (0.070 to 0.118 inch). The heater block of our extruders and the nozzles are made from copper for faster and more stable temperature control. Several nozzle sizes will be available for printing various sizes and types of parts.

Our latest version of this extruder is larger than current extruders and has design improvements to allow it to take advantage of the higher temperature ranges required by the various types of thermoplastic available in the larger diameter sizes. These plastics have properties that will greatly enhance a 3D printer's usefulness by allowing it to make parts that can be used in many different environments.
The following are some of the types of common thermoplastic welding rod along with several uses and properties that would make them an attractive candidate for a 3D printed part.

PVDF Chemical restiveness of PVDF and its long lasting strength will make this a popular choice for laboratories or clean-rooms where tanks, tank furniture, fittings or cassettes could be made quickly from a computer library of components or as needed from a 3D CAD drawing for a custom application.

PVC 1, PVC 2 & CPVC with their ability to withstand UV would be great for any sort of outdoor applications or unique PVC pipe fittings. These materials also resist acids and alkalies and are commonly used in chemical processing applications.
Polypropylene makes parts with a hard surface and resists many chemicals and solvents. One interesting use for this material is its ability to make parts that have a living hinge on them, like used on the lid of a Tic-Tac candy box. It is also commonly used in clean rooms for chemical benches, tanks and enclosures.

Polyethylene available in low or high density formulations are very resistant to moisture as well as many chemicals.

HMW makes parts with a slippery surface useful for many industrial applications such as chain guides or rollers. It has excellent impact strength and good wear resistance.

Polycarbonate is synonymous with impact resistance. This transparent material has excellent impact resistance over a wide temperature range. Parts made from this plastic would have great strength and flexibility.

Our extruders, are of course, not limited to these materials and can also extrude ABS, PLA, any of the Taulman filaments, nylon, PETT, HIPS, PVA and others from 1.75mm diameter to 4.75mm diameters (0.070 to 0.188 inch). Many of these materials have previously not been available to the 3D printer community. It is our hope that this extruder will change that and be a benefit to all 3D printer owners who need parts with better strength, chemical resistance, UV resistance or other properties that these various plastics can provide.

Why are we so proud of our extruders?

• Very compact design with a mid mounted, integrated heat sink for better cooling of both filament drive parts and stepper motor.
• Extremely solid one piece aluminum body with mounting options on top, bottom or either side.
• Copper heater block and nozzle for faster, more stable temperature control.
• Plans for making two sizes of extruder, a NEMA 17 stepper motor size for smaller 3D printing machines or the larger, more powerful NEMA 23 stepper motor extruder for larger, faster moving 3D printers.
• Precision quality, our extruders feature a spring loaded dual wheel filament drive mechanism for positive filament control. The drive wheels are made from steel and are hobbed for traction.
• Our NEMA 23 extruders will be able to accommodate 5 filament sizes (1.75mm, 3mm, 1/8, 5/32 and 3/16 inch diameter filaments) and multiple plastic options with nozzle options for various materials and extrude diameters.

Hot end made from copper

The Cartesian Co. printer EX¹ transforms electronics and prototyping in the same way that 3D printing has made things possible that were inconceivable even 5 years ago.
The EX¹ printer is not designed to create any 3D object like normal 3D printers. It’s been crafted and designed for one key purpose, to allow you to 3D print circuit boards, layering silver nano particles onto paper or any suitable surface to rapidly create a circuit board. In 2011, an article in Wired said that within two years 3D printers could print electronic circuits. Two years to the day, we’re announcing the EX¹, a printer that allows you to rapidly 3D print circuit boards.
The process is as easy as clicking File > Print. This lets you create electronics, just as you've envisioned - wearable electronics, paper circuits, printed computers or whatever you imagine. A 3D printer creates the objects of your imagination; the EX¹ lets you create the electronics of your imagination.

Wearable circuits

One capability of the EX¹ we're really excited about is the ability to print straight onto fabric. Anyone who has used conductive thread will tell you how frustrating it is when the thread breaks but you can't find the break! With the EX¹ you can print circuits straight onto the material of your choice.

How it works

The reason we created the EX¹ is simple; we got sick of making PCBs by hand. We got so sick we set out to find a way to make circuits quickly and effortlessly.
The basic principle of operation is simple. Two inkjet cartridges similar to the ones in your desktop printer print images on a substrate, but instead of ink they lay down two different chemicals. When these two chemicals mix, a reaction occurs to produce silver nano particles, leaving a silver image on the substrate.

After a year of working on the EX¹ we believe we've finally created a printer that will allow people to design and make radically new things. With a print area of 17.5 x 8cm (6.9 x 3.2in) you'll be able to print boards well above the size of what you can design in the free version of Eagle. At a size of 43 X 32 X 17cm (17 x 12.6 x 6.7in) its roughly the same size as your Canon or Epson printer at home. Weighing in at only 6kg (13.5lb) it's very portable and will be perfect to take to work or your local hackerspace.

Software

How hard is it to use your home printer or office photocopier? Not hard (we hope), and that's exactly what we've aimed for with our software.
But of course printing electronics isn't exactly the same as printing a cute baby photo. We give you complete flexibility with our software, anything from just importing an image and clicking print, all the way through to having control over every printing variable.
We've included presets and tools to make getting into making electronics as easy as possible, while at the same time allowing experienced pros to push the boundaries of what can be done.

Materials

As well as making it easy for people to create complex circuits we wanted to make it easier to put them together. You can always solder the circuits but if you're not at that stage yet we've been successfully using conductive glues that's as easy as finger painting. In fact, when you use it with a paper circuit it almost IS finger painting!
We're developing new ways of treating and coating everyday materials to be printed on, so there's nothing holding you back from creating whatever your heart desires.
The materials you can print onto is only half of the equation. Equally important are the inks you're using to do so. We're actively working on new ink formulations and processes to ensure using your printer is as easy and reliable as possible.

The inks we are using are very safe and we won't be gouging you for refills like some printer companies out there (we hate that too!).

http://www.cartesianco.com/

They finished successful Kickstarter:

http://www.kickstarter.com/projects/cartesianco/the-ex1-rapid-3d-printing-of-circuit-boards

Here they demonstrate printed electronic circuits on 3d printed PLA:

Working electronic circuit printed on paper

Printed wearable electronic circuit

This 3D printer board electronics has been designed and developed using all the great contributions and feedback from the RepRap CloneWars group in Spain. All shortcomings from other similar boards have been addressed providing an affordable yet feature rich 3D printer electronics. The SAV MkI, improves upon the previous production-grade electronics set (Gen6, sanguinololu) by adding well dimensioned power MOSFETS, SD card support, on-board regulated 3.3V to connect to 3.3V level peripherals such us Bluetooth, as well as improving on USB link's reliability and reducing cost by eliminating the FTDI UART chip.
The SAV MkI is a derivative of Teensylu and the Printrboard, an AT90USB1286 development board originally based on Sanguinololu. The Atmel AT90USB1286 MCU has an on-chip USB, removing the need for the FTDI UART (USB-to-serial) IC. On-chip USB means that you will get faster firmware upload times, communications, g-code transfer and reduce the time file transfers take from the host to the on-board microSD card. The AT90USB connects at any baud rate regardless of firmware configuration, and operates virtually free of serial communication errors/pauses.

In addition, the SAV MkI has broken out the second UART with its levels adjusted to 3.3V logic. You will be able to connect any HC-05 or HC-06 bluetooth dongle to wirelessly control your printer.
Features
Feature rich yet affordable 3d printer electronics. The SAV MkI has been designed after taking feedback from the Clone Wars RepRapers out there. We have come through with an electronics that we believe will meet your expectations.

• Hotend and heatbed well dimensioned FETs that can take up to 15A without heat-sinks.

• High speed native USB interface connectivity going up to 12Mbps so that there is no lag on your prints.

• As opposed to the 38400-115200 baud via FTDI. The end result is: virtually no serial communication errors (common with Sanguinololu and Generation_6_Electronics).

• 12V built-in fan controller for your layer fan or hot end cooling.

• Micro SD reader for autonomous printing.

• Bluetooth dongle (dongle not provided, tested with HC-05 and HC-06) interface adapted to its logic levels for wireless operation.

• Expansion bus to connect a keyboard and LCD.

• Support for 4 standard pololu compatible stepper motor drivers.