Author Topic: New 3D Printer by MarkForged Can Print With Carbon Fiber  (Read 588 times)

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New 3D Printer by MarkForged Can Print With Carbon Fiber
« on: January 28, 2014, 03:08:18 AM »
Gregory Mark co-owns Aeromotions, which builds computer-controlled racecar wings. To make those wings both strong and lightweight, they use carbon fiber. No surprise there—it's the material of choice for many advanced motorsports parts. The problem is that making custom racecar parts out of carbon fiber is daunting. The only real method available is CNC machining, an expensive and difficult process that requires laying pieces by hand.

 To improve the process, Mark looked to 3D printing. But nothing on the market could print the material, and no available materials could print pieces strong enough for his purposes. So Mark devised his own solution: the MarkForged Mark One, the world's first carbon fiber 3D printer.

 Mark debuted his Boston area-based startup MarkForged at SolidWorks World 2014 in San Diego with a working prototype. The Mark One can print in carbon fiber, fiberglass, nylon and PLA (a thermoplastic).

 "We took the idea of 3D printing, that process of laying things down strand by strand, and we used it as a manufacturing process to make composite parts," he told PopMech. "We say it's like regular 3D printers do the form. We do form and function."

 What you notice first about MarkForged's printer is its amazing simplicity. With an anodized aluminum unibody and a translucent printing bed, it looks like the Mac of 3D printing. The Mark One employs kinematic coupling for consistent bed leveling, meaning you won't need to worry about making sure the bed is leveled correctly after each print. It's also compact, measuring 22.6 inches wide, 14.2 inches tall, and 12.7 inches deep—a good desktop size.

The main advantage of the Mark One: It can print parts 20 times stiffer and five times stronger than ABS, according to the company. It even has a higher strength-to-weight ratio than CNC-machined aluminum. The racecar wing, for example, is printed with a nylon outershell and honeycomb structure, with a carbon fiber reinforced core. Mark says that he imagines this machine is for anybody who wants to print in a material as strong as aluminum. Beyond racecars, it could be useful to industries like prosthetics.

 "There are a bunch of people who are interested in the prosthetics side," he says. "There's a whole fit component. It has to fit on your body. That's something that's more art than science, you want to print out a whole bunch of different versions and test them out," Mark says. "But then when you have your final version, you want to make exactly that, but really strong. [With] this printer‚ once you want to make it strong, you print it in composites."

 The Mark One isn't limited to commercial use. With a price $5000, Mark wants to make sure printing in carbon fiber is available to consumers as well.

 "It's a material that everybody knows, but probably most people haven't used. So we made the price low and you can start using it. We wanted to make it really easy for people to start printing with it, so they can explore prosthetics, custom bones, tools, and fixtures."

 It's potentially a huge step for 3D printing, which has been limited mainly to plastics, limiting its real-world applications. The MarkForged also could help the prototyping phase for companies producing aluminum and carbon fiber products by providing an even more precise model.

 The MarkForged Mark One will be available for pre-order starting in February. You can sign up for notifications at the company's website. Units will start shipping in the second half of 2014.


http://www.popularmechanics.com/technology/gadgets/news/new-3d-printer-by-markforged-can-print-with-carbon-fiber-16428727?click=pm_latest

Offline Oceander

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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #1 on: January 28, 2014, 02:20:18 PM »
interesting.  remember that lower receiver that was 3D printed and successfully worked?  That was made out of a durable plastic resin - durable, but still plastic - a receiver 3D printed with this machine would be orders of magnitude superior.

Offline Chieftain

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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #2 on: January 28, 2014, 02:43:13 PM »
Great technology with lots of potential.  What we need is an inexpensive way to extract pure carbon from a source and produce it in a pure enough form that is usable for this technology and inexpensive to boot.  Even better would be a large but compact carbon production facility suitable for orbit.  Feed it carbonaceous asteroids and print out carbon fiber structural members for all kinds of zero and micro gravity construction projects.

 :beer:

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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #3 on: January 28, 2014, 11:42:13 PM »
Great technology with lots of potential.  What we need is an inexpensive way to extract pure carbon from a source and produce it in a pure enough form that is usable for this technology and inexpensive to boot.  Even better would be a large but compact carbon production facility suitable for orbit.  Feed it carbonaceous asteroids and print out carbon fiber structural members for all kinds of zero and micro gravity construction projects.

 :beer:

Didn't you mention something else like this a few days/weeks back?  I agree that it would definitely make space exploration/colonization measurably easier.  I only wish I could live long enough to both see it, and participate in it.

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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #4 on: January 29, 2014, 12:27:29 AM »
It would also make planes lighter and stronger.

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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #5 on: January 29, 2014, 12:34:29 AM »
It would also make planes lighter and stronger.
A neighbor of mine worked at Boeing, and years ago he worked with his son, fabricating skim boards, out of a honeycomb core, with resin on the outside. They did it in the garage.

Now his son builds racing airplanes from modern lightweight plastic materials. Maybe it is carbon fiber.

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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #6 on: January 29, 2014, 12:37:47 AM »
A neighbor of mine worked at Boeing, and years ago he worked with his son, fabricating skim boards, out of a honeycomb core, with resin on the outside. They did it in the garage.

Now his son builds racing airplanes from modern lightweight plastic materials. Maybe it is carbon fiber.

The Boeing 787 Dreamliner uses carbon.. The 'composite' design - using mixed materials such as titanium and carbon fibre - is believed to have been a spur for rival Airbus to incorporate carbon fibre in future aircraft. 50 percent of the airplane uses a carbon and plastic mesh.
« Last Edit: January 29, 2014, 12:39:29 AM by SPQR »

Offline EC

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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #7 on: January 29, 2014, 03:34:17 PM »
Love carbon fiber. It's amazing stuff, and, layered properly with kevlar, asbestos (yeah, I know, toxic but totally fireproof) and titanium mesh it makes a light weight, high strength armor. The 24F had that as it's belly armor and the Ka-50 is armored throughout. Still got the duraluminum for the actual airframe (that is a bitch to weld and keeps cracking if you play around with multi G maneuvers), but it really does cut down on weight and increase survivability.
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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #8 on: January 30, 2014, 01:55:12 PM »
Love carbon fiber. It's amazing stuff, and, layered properly with kevlar, asbestos (yeah, I know, toxic but totally fireproof) and titanium mesh it makes a light weight, high strength armor. The 24F had that as it's belly armor and the Ka-50 is armored throughout. Still got the duraluminum for the actual airframe (that is a bitch to weld and keeps cracking if you play around with multi G maneuvers), but it really does cut down on weight and increase survivability.

Asbestos isn't a problem so long as it's incorporated into something else entirely and isn't opened up or exposed.  That's why a lot of the asbestos remediation projects that get undertaken are stupid; take, for example, the tiles in the student center at my undergrad uni.  The tiles were glued to the concrete subfloor using an asbestos-containing glue; about 20 years ago the school covered the entire building in plastic and spent one entire summer grinding the tiles and glue up, down to the raw concrete.  The grinding up actually posed more of a risk of asbestos exposure than simply leaving the tiles in place did.  Stupid is as stupid does.

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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #9 on: January 30, 2014, 02:14:57 PM »
Asbestos isn't a problem so long as it's incorporated into something else entirely and isn't opened up or exposed.  That's why a lot of the asbestos remediation projects that get undertaken are stupid; take, for example, the tiles in the student center at my undergrad uni.  The tiles were glued to the concrete subfloor using an asbestos-containing glue; about 20 years ago the school covered the entire building in plastic and spent one entire summer grinding the tiles and glue up, down to the raw concrete.  The grinding up actually posed more of a risk of asbestos exposure than simply leaving the tiles in place did.  Stupid is as stupid does.
Sealing the asbestos in is called "encapsulation."

There is an entire "sub industry" for removal of "cottage cheese" ceiling textures, that violates laws daily.

They are supposed to test, remove the toxic materials, transport them for disposal in certified waste dumps.

In reality, companies fairly openly do it without the legal procedures.

If given the costs and implications of both methods, most liberal democrats would opt for the cheap, but illegal method.

But when it comes to taxpayer funds, those jurisdictions, such as old schools, will follow the procedures to the letter, and spend many multiples of cost.

Offline Oceander

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Re: New 3D Printer by MarkForged Can Print With Carbon Fiber
« Reply #10 on: January 30, 2014, 02:58:24 PM »
Sealing the asbestos in is called "encapsulation."

There is an entire "sub industry" for removal of "cottage cheese" ceiling textures, that violates laws daily.

They are supposed to test, remove the toxic materials, transport them for disposal in certified waste dumps.

In reality, companies fairly openly do it without the legal procedures.

If given the costs and implications of both methods, most liberal democrats would opt for the cheap, but illegal method.

But when it comes to taxpayer funds, those jurisdictions, such as old schools, will follow the procedures to the letter, and spend many multiples of cost.

of course.  they did the same thing in a number of the older dorm buildings, which was if anything even stupider since that is where people actually live.


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