In the current landscape of FFF/FDM desktop 3D printing, there's an impressive array of materials available—something that would have seemed impossible just a few years ago. Back then, the idea of printing flexible materials was more of a dream than a reality. Today, however, flexible 3D printed wires are becoming increasingly common. Despite this progress, many potential applications of these materials remain untapped, as they haven't been widely explored yet.
This is where Steve Wood comes in. A passionate 3D printing enthusiast, he has dedicated himself to pushing the boundaries of flexible materials. Recently, he discovered a clever technique to print both flexible and rigid wires within the same layer. His breakthrough came while working on a project called "Flesh and Bones," which aimed to create a soft yet functional prosthetic hand.
Wood explained, “The concept behind 'Flesh' was to develop a prosthetic hand that feels soft to the touch but remains structurally strong.†To achieve this, he needed a way to print both flexible and rigid materials in the same layer. He 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, allowing for material switching.
However, the challenge wasn’t just about switching materials—it was about doing it seamlessly within a single layer. The Cyclops uses a dual Bowden system, which works well for rigid filaments but struggles with ultra-soft ones like Filaflex. To overcome this, Wood switched to a double direct drive system, enabling him to print two different colors of flexible wire at the same time. He modified the existing dual extruder setup to fit the Cyclops hot end, creating a more compact and efficient design.
To ensure smooth transitions between materials, Wood also had to adjust the slicing software. He used Cura’s feature to print a small, disposable cube during material changes. This allowed the printer to clear the old material from the hot end before continuing with the new one. As he noted, “Although the Cyclops can switch materials quickly, it doesn’t happen instantly.â€
He also emphasized the strong bond between different material areas, thanks to the sticky nature of Filaflex and the settings in Cura. By adjusting the overlap between materials, users can control the adhesion and color sharpness. An increased overlap improves bonding but may reduce color contrast.
Looking ahead, Wood plans to experiment with what he calls “pseudo-mixed materials.†Rather than a true hybrid hot end, he wants to explore how varying the ratio of flexible and rigid filaments affects the final output. He’s already developed a tool called Gcode Filament Mixer to help with this.
His ultimate goal is to create a more realistic 3D-printed prosthetic hand—one that combines a rigid internal structure with a soft, flexible exterior. With continued experimentation and innovation, he hopes to bring this vision to life.
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