In the rapidly evolving world of FFF/FDM desktop 3D printing, there's now an impressive range of materials available—something that was once just a dream. Not long ago, printing with flexible filaments was considered a challenge, but today, flexible 3D printed wires are common and widely used. Despite this progress, many potential applications of these materials remain unexplored.
Steve Wood, an experienced 3D printing enthusiast, has been deeply interested in exploring the possibilities of flexible materials. Recently, he developed a clever technique to print both flexible and rigid filaments in a single layer, which could revolutionize how we approach multi-material 3D printing. His project, "Flesh and Bones," aimed to create a prosthetic hand that felt soft to the touch but maintained structural rigidity.
To achieve this, Steve upgraded his RepRap-style printer, Orca 0.43, by replacing its original hot end with a new E3D Cyclops model. This hot end features dual filament input but only one nozzle. The challenge was to manage both flexible and rigid filaments within the same layer. The standard Bowden system didn't work well with ultra-soft Filaflex, so Steve opted for a dual direct drive setup instead. This allowed him to print two different colors of flexible wire simultaneously.
He also had to modify the slicing software to ensure smooth material transitions. Using Cura, he added a small disposable cube on the side of the print, which helped clear the old material before switching to the new one. This process ensured that the transition between materials was seamless and efficient.
The bond between different materials turned out to be very strong, thanks to the sticky nature of Filaflex and the settings in Cura that controlled the overlap between materials. Increasing the overlap improved adhesion but reduced color sharpness, offering a trade-off that users can adjust based on their needs.
Looking ahead, Steve plans to experiment with what he calls "pseudo-mixed materials." While not a true hybrid, this method involves feeding both flexible and rigid filaments into the hot end at the same time, creating a toothpaste-like consistency. He’s already developed a tool called Gcode Filament Mixer to help fine-tune the feed rates and ratios.
His ultimate goal is to create more realistic and functional 3D printed prosthetics—hands that have a rigid internal structure and a soft, flexible exterior. With continued experimentation, he hopes to push the boundaries of what's possible with multi-material 3D printing.
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