Light Weight Plane

November 15 update: Now with video of the first flight! Scroll down to see the spectacular footage!

When we launched our light weight filament LW-PLA earlier this year we saw a lot of handy applications: cosplay, medical instruments, grips. Every print where weight is of the essence. The most positive replies we got were from the drone and RC plane community. One of the companies specialized in RC planes, Eclipson Airplanes from Spain, contacted us and were very interested in our latest offering. During the summer the Eclipson team worked on a light weight plane design specifically made to be printed with LW-PLA. Here is a first look at their Model V plane:

All designs and images by Eclipson Airplanes

A few details about the Model V plane:

  • Total weight of the printed parts 170 gr
  • Ready to flight weight (estimated) 380 gr
  • Wing span 1.370mm
  • Wing area 16 dm2
  • Wing loading 24gr/dm2

You can find more information about this design on the dedicated Model V page.

“This means that this airplane holds a new world record, it is the lightest RC plane in terms of wing loading.”

  • Team Eclipson

Rendering with Eclipson logo

When printed with regular PLA, the plane would weigh twice as much and as we all know: every gram counts in aviation. As Eclipson states on its homepage:

“Drag and weight are the two main enemies of any flying machine, reduce those two forces to the minimum was one of the main goal of this project since the conceptual phase.
The drag was reduced thanks to its streamlined shapes, clean design, V tail, high aspect ratio or winglets. Special mention deserves the wing, which is simply the best we have ever designed, this wing has a great balance between safety (docile stall characteristic) efficiency (high lift to drag ratio) maneuverability (high roll rate) and strength. Landing gear, tail and wing can be detached from the fuselage allowing you to print only damaged parts in case of crash.”

Not only did the LW-PLA reduce weight significantly, the Eclipson team also found out that LW-PLA worked extremely well for them when printing the landing gear thanks to its flexibility.

The Model V light weight plane will be for sale from Eclipson from mid-October. Keep an eye out for this excellent plane!

Located in Madrid, Spain, Eclipson Airplanes is specialized in the design of RC Planes and they have already several models available (click here to see their portfolio).

The Model V design is available for purchase at Eclipson (follow this link) and it has already made its maiden flight!

 

About LW-PLA

LW-PLA is the first filament of its kind using an active foaming technology to achieve lightweight, low density PLA parts. At around 230C this material will start foaming, increasing its volume by nearly 3 times. Users can decrease material flow by 65% to achieve lightweight parts, or use the expanding properties to effectively reduce print time by using big layer heights or single extra thick perimeters.

 

Decreasing flow means using less filament. Therefore users can expect to print 2-3 times more parts using LW-PLA compared to a regular PLA spool. LW-PLA prints in a fantastic matte looking surface finish and is very easy to post process. Any oozing or stringing artifacts rub right off and the surface is easily sanded for a smooth finish. Find out more here.

Curious how to print with LW-PLA? Find out more in our tutorial!

LW-PLA is available in Black and Natural and is available now. We ship daily, worldwide and from stock.

Lamp Shades

There is no restriction these days where one can find 3D printed parts: gadgets, end parts, tooling, prototypes and, more and more, design pieces that you can find in any home these days. One great application is to use 3D printing to make unique and customized lamp shades. Companies like Gantri are doing amazing things in this field and we recently came across the work of Nicolas Muller, who designed the Shiny Leaves Lamp Shade.

Design and all images by Nicolas Muller

Nicolas uses our nGen Clear to print the lamp shades on his self-built printer using E3D extruder and hot ends. He even used nGen to print parts of the printer, so he is clearly a fan! The ease of use and clarity of the filament has made it the go-to filament for Nicolas.

Nicolas is an architect and enjoys working on lamp shades and other designs when he finds the time. He is located in Strasbourg, France. From time to time he publishes his work on his Facebook page.

Nicolas’ website is still under construction but you can contact him if you would like to have more information: contact@acidstudio.fr. We will definitely follow him and his amazing work!

ABOUT NGEN

A little over three years ago, by the end of 2015, we released a new all-round material called nGen, next Generation, based on Eastman Amphora AM3300. We believed then (and still do) that this filament was a next step for 3D printing materials. It was our goal to bring a filament to the market that has functional properties, looks astonishingly good and prints like a dream.

nGen has been a hit ever since. This is not without reason. It is true all-round material suitable for most day to day 3D printing activities. Its chemical make up ensures a very consistent quality. An advantage over PLA is its elevated temperature resistance: 80 degrees instead of 45 degrees, so even in hotter climates (or a hot summer day) the material holds up extremely well. Below is a comparison chart of several of the Amphora based filaments compared to commodity materials like ABS and PLA.

You can read more on our dedicated landing page or our blog about co-polyesters.

nGen is an amazing material which enables users to create parts with gorgeous detail and the benefit of long term stability. Don’t just take our word for it. Below are some of the reviews that our users posted in our webshop:

“Its just the perfect Filament for me!”

“Printing as easy as PLA, but with better material properties.”

“nGen is very predictable and strong.”

“nGen is always my “go to” filament. It just prints beautifully. It’s strong, handles heat well, reliable, and just looks great.”

“… prints like butter 🙂 and the finish is absolutely perfect.”

Water Tap Splitter

In the past few years we have written several times about the advantages that 3D printing has for the casting industry. You can find the links to those articles at the end of this blog. Today we show you a practical example of a water tap splitter and how 3D printing not only saves time in the development process, but also saves costs significantly.

Water tap splitter design by colorFabb

Go to our Landing Page to find out more!

Using 3D printing in investment casting reduces cost and adds flexibility to the process. PLA/PHA is a natural choice for this process where the entire print is burned out. What started thousands of years ago with beeswax has now evolved to patterns made with 3D printing. The printed pattern is coated with ceramic, then the printed pattern is burned out and the metal poured into remaining shell leaving a complete casting.

 

The original which we replicated for this blog

Instead of investing in tooling to produce a wax pattern, foundry companies can choose to 3D print their patterns in a material suited for investment casting. ColorFabb PLA/PHA Natural is a material uniquely suited for investment casting. It’s an easy printing material capable of creating complex shapes with great smooth surface finish and will work with most desktop and industrial type FFF 3D printing machines.

For this print we used the Stacker S4 XL. Printing 4 pieces at a time took about 22 hours at 0.12mm layer height and each part weighs approximately 140 grams (and is eventually turned into a 1kg of stainless steel part when all is said and done).

With the colorFabb PLA/PHA filament we can enable the investment casting with more easy access to small volume production. Prototyping and small batches of patterns can now be 3D printed, eliminating the need for mould making to save both the costs and time needed for this process. This also ties in nicely with new design trends such as Generative Design, allowing Investment Casting to be an interesting alternative to 3D printing metal for various applications.

Below are the steps taken after we finished the print:

Putting the print on the wax tree

 

Putting the tree in the sand

 

Drying the tree

 

Filling the tree with steel

 

The end result

One of the big advantages of FDM/FFF 3D printing in this case is the decrease of costs. This part was made for about € 100 (compared to much higher costs elsewhere for a similar one-off production:

 

About Stacker

As many of you know, we are the distributor of Stacker 3D printers in Europe. We have been working with Stacker ever since their first prototype and now have several in our print lab. In the past 5 years we have seen 3D printing emerging from a hobby market to more professional uses. A lot of our users are using 3D printing to make a living or at least support their business in one way or another. We recently published two blogs about Dutch companies Optima and Mifa and their use of Stacker 3D printers.

The Stacker printers are industrial grade FFF 3D printers. Multiple print heads and a large build volume make them versatile printers. Small series production or large scale prototyping are no problem for the Stacker printers! This Minneapolis, USA, based manufacturer produces highly reliable printers and is a perfect match for any professional looking for serious 3D printing. You can find the full product specifications on our dedicated Stacker page.

The Stacker S4 XL has a bigger build volume than its smaller siblings and other advantages:

  • Huge Build Volume 610 x 610 x 610mm (24 x 24 x 24″)
  • Closed loop servos for ZERO lost steps
  • Compatible with Stacker’s Direct Direct drive extruder
  • Four Print Heads for 4X print speeds
  • High Precision Linear Motion
  • Amazing Print Quality
  • Works with almost any Filament

For Stacker the term “industrial grade” is not a hollow marketing term. It means their printers are designed for extra long service life, extremely low maintenance and that the printer will maintain its positional accuracy throughout its life cycle. This printer has been designed to be used in a professional environment, be it for large prototypes or small series production.

Interested? Get a quote or contact us!

Previous posts about investment casting:

Batman bust

Our filaments already look great when printed, but we get a lot of questions about post-processing. Not only materials where this is kind of necessary (like bronzeFill or copperFill), but also other materials are often the subject of some serious post-printing work to make the printed object truly unique. For this post, our technical development manager (and part of the Team colorFabb from the very beginning) Gijs Houdijk takes you by the hand to show how he post-processed this awesome Batman bust, designed by David Östman.

Design at MyMiniFactory

To begin with, we used our very own PLA Semi-Matte White as the basis for this print, using the standard PLA settings on the Makerbot Replicator 2. For this print we used a 0.15mm layerheight, lower layerheights equals less sanding to get smooth areas.

Well, this Batman bust already looks pretty great, but Gotham’s Caped Crusader can even look better! Below are the post-processing steps that Gijs took.

1. Primer & Sanding

I usually start with a couple of layers of primer. After this I’ll start with sanding, using 220 grit. Then add another layer of primer and continue with sanding. My goal is to smooth out af much as possible the exposed area’s, without loosing detail in the print. The smoother the exposed area’s are, the better they will look after Step 3 ‘Wheathering’.

2. Silver base coat

I used Vallejo Acrylic Metal Color for the base silver metal coat. Instead of using an airbrush I used regular brush to apply paint to the model. It’s a very thin paint which coats really really well. It also dries super fast and is very easy to get an even coat.

3. Weathering the model

After the base coat I apply black spray paint to the model and immediately remove as much as I can with a soft cloth. Don’t let the pain dry, you want to wipe it off while it’s still wet. You can do this one side of the model at the time. The smooth exposed area’s will be wiped clean, revealing the metal looking surface. All the nooks anc crannies will stay dark because of the black spray paint, creating a nice contrast with the metal looking surfaces.

4. Glue both parts together

I used LOCTITE® 3DP INSTANT BONDER. Great feature of this glue is that it hardly turns white after it’s set, which some CA glues do tend to have. Loctite is available in the colorFabb webshop.

 

PLA Semi-Matte White is a great material for architects and model makers looking for a different aesthetic. Our semi-matte PLA filament eliminates the glossy appearance seen on most PLA 3D prints. The highlights on the surface will be less visible, resulting in an overall cleaner and much higher quality look. This makes it also a good choice to use as a base for prints that need to be post-processed.

As with its black sibling PLA Semi-Matte White contains no fibers and prints at regular PLA temperatures and settings. The material is as reliable and easy to work with as any other PLA type material.

Want to read more about post-processing other materials? Check out the links below:

Sand casting

We have written several times about using 3D printing for investment casting, but we also see an increased use of our filaments for sand casting. It is a metal casting process where sand is being used as the mold material. With around 60% of all metal castings being made with sand casting, it is a very interesting technology for 3D printing.

Design by Slogaholik (Grabcad link)

The sand casting process employs techniques that produces shaped parts of nearly any design, including very large parts and those with internal passageways. The process is referred to as sand casting because the mold that contains the cavity into which metal is poured is made of compressed or compacted sand. The mold cavities and gate system are created by compacting the sand around models called patterns, by carving directly into the sand, or by 3D printing.

We have printed one halve of a pattern for the sand casting process, here using PLA Economy Silver on the Stacker S4 XL. The pattern is used to form the cavity in sand in which metal can be poured afterwards.

The total printing time was 4 days and we used 3.1kg of material for this print, using a 0.8mm nozzle, 0.16mm layer height and 13% infill every 2 layers.

ABOUT THE FILAMENT

PLA Economy offers a great value for your money. One spool consists of 2.2kg of filament for a dirt cheap price of a little over € 35 (ex VAT and shipping). It is a different grade than our range of PLA/PHA, but we guarantee the same colorFabb quality. Our filaments are readily available from our webshop. You can use the standard PLA settings if your printer has these pre-defined and these should work fine.

You can also opt for the PLA Economy Value Pack: order four spools as a value pack which lowers the costs per spool immediately.

Buy PLA Economy  Buy PLA Economy Value Pack

PLA Economy is very well suited for the maker who needs quality at an affordable price. It is a perfect filament for large volume and small series production, made with the guaranteed colorFabb quality that we are known for. It has been one of colorFabb’s most popular filaments ever since launching 3 years ago.

 

ABOUT STACKER 3D PRINTERS

The Stacker 3D printers are industrial grade FFF 3D printers. Recently the even larger Stacker S4 XL was added to the portfolio. Multiple print heads and a large build volume make them versatile printers. Small series production or large scale prototyping are no problem for the Stacker printers! This US based printer is very reliable and is a perfect match for any professional looking for serious 3D printing. You can find the full product specifications on our dedicated Stacker page.

For Stacker the term “industrial grade” is not a hollow marketing term. It means their printers are designed for extra long service life, extremely low maintenance and that the printer will maintain its positional accuracy throughout its life cycle. This printer has been designed to be used in a professional environment, be it for large prototypes or small series production.

The Stacker printers on display in our print lab

As many of you know, we are the distributor of Stacker 3D printers in Europe. We have been working with Stacker ever since their first prototype and now have several in our print lab. In the past 6 years we have seen 3D printing emerging from a hobby market to more professional uses. A lot of our users are using 3D printing to make a living or at least support their business in one way or another.

Interested? Get a quote or contact us!

Rolling Jack

With a lot of 3D printing tools at our disposal it becomes easier (and more fun!) to print large, multi-material prints. As a visual prototype we printed this rolling jack with various materials in our print lab on the Stacker S4 XL.

Design by Sevatar (Grabcad link)

We printed on the Stacker S4-XL with a 0.6mm nozzle for an optimal balance between speed and quality. It took quite some time to print this one:

  • Main body: 70 hours – 1kg material used
  • Other silver parts: 65 hours – 850 gr. material used
  • Black parts: 20 hours – 280gr
  • White parts: 12 hours – 140gr
  • Handle: 2,5 hours – 30 gr.

The rolling jack is entirely made out of PLA and we used various PLA grades from our portfolio where they would fit best, aesthetically:

All these materials are available in our webshop and ship from stock! All parts of the rolling jack were glued together with Loctite glue, which is now also available in our webshop! Check out the accessories we currently offer by clicking here.

 

ABOUT STACKER 3D PRINTERS

The Stacker 3D printers are industrial grade FFF 3D printers. Recently the even larger Stacker S4 XL was added to the portfolio. Multiple print heads and a large build volume make them versatile printers. Small series production or large scale prototyping are no problem for the Stacker printers! This US based printer is very reliable and is a perfect match for any professional looking for serious 3D printing. You can find the full product specifications on our dedicated Stacker page.

For Stacker the term “industrial grade” is not a hollow marketing term. It means their printers are designed for extra long service life, extremely low maintenance and that the printer will maintain its positional accuracy throughout its life cycle. This printer has been designed to be used in a professional environment, be it for large prototypes or small series production.

The Stacker printers on display in our print lab

As many of you know, we are the distributor of Stacker 3D printers in Europe. We have been working with Stacker ever since their first prototype and now have several in our print lab. In the past 6 years we have seen 3D printing emerging from a hobby market to more professional uses. A lot of our users are using 3D printing to make a living or at least support their business in one way or another.

Interested? Get a quote or contact us!

Jerrycan

Real size prototyping can be a problem on most desktop 3D printers. With build limits of 30cm squared, at best, the size of the print needs to be small – or one has to start chopping up the print and assemble it later. With the Stacker S4- XL one can print prototypes in their real size, like this jerrycan:

Design by Langgeng (Grabcad link)

The 10 liter jerrycan took 77 hours to print on the Stacker S4-XL and consumed 1kg of filament. For the filament, we used our Color on Demand Traffic Red, RAL 3020.

About Stacker 3D Printers

The Stacker 3D printers are industrial grade FFF 3D printers. Recently the even larger Stacker S4 XL was added to the portfolio. Multiple print heads and a large build volume make them versatile printers. Small series production or large scale prototyping are no problem for the Stacker printers! This US based printer is very reliable and is a perfect match for any professional looking for serious 3D printing. You can find the full product specifications on our dedicated Stacker page.

For Stacker the term “industrial grade” is not a hollow marketing term. It means their printers are designed for extra long service life, extremely low maintenance and that the printer will maintain its positional accuracy throughout its life cycle. This printer has been designed to be used in a professional environment, be it for large prototypes or small series production.

The Stacker printers on display in our print lab

As many of you know, we are the distributor of Stacker 3D printers in Europe. We have been working with Stacker ever since their first prototype and now have several in our print lab. In the past 6 years we have seen 3D printing emerging from a hobby market to more professional uses. A lot of our users are using 3D printing to make a living or at least support their business in one way or another.

Interested? Get a quote or contact us!

 

About Color on Demand

With Color on Demand we have already matched hundreds of colors. We have published the RAL references (over 100 already) online which can readily be ordered. But we can match more than only RAL colors. Some customers send us physical references, others send us well-known color references like CMYK, Pantone or other standards which we then try to match as close as possible.

RAL 3020 is one of the brightest and most stunning reds in our portfolio

With Color on Demand we re-invented the way makers can choose colors. No longer you are bound to the colors that have been pre-selected by filament manufacturers anymore. Now you can order the color you actually need and want.

We have already matched over 100 RAL colors, which can easily be ordered online. Click here to see our collection. You can order as from one 750 grams spool! If we have not matched your favorite color, request it by using our online form. Starting from a 2kg spool we match the specific color you want, based on RAL, other well-known color references or a physical reference.

With Color on Demand you can say “yes” to that print job which needs a specific color or a look you have been waiting for. Stun your colleagues, family or other makers with your prints. You could already print one-of-a-kind designs, now you can also make them look unique!

Check out more recent Color on Demand prints by clicking here. Make sure you read our color disclaimer. Want to know more about Color on Demand, check our our FAQ page.

Surfboard fin

3D printing has been used for prototyping since the dawn of mankind. Literally. We have found that with certain prototypes weight is of the essence and with our brand new lightweight filament LW-PLA we have solved the problem of many prototypers: weight reduction. A great example of this is this in-house designed surfboard fin, part of a bigger project. Weight was of the essence and we needed the part to be as light as possible.

As you can see, the weight has been reduced significantly. It is not the weight of the world in absolute terms, but with print jobs where every gram matters, like these foam core parts LW-PLA is the solution for a lot of users.

We printed this surfboard fin on the Stacker S4 with 0.2mm layer height, 250C and 40% flow.

Curious how the print with LW-PLA? Learn more here!

LW-PLA is the first filament of its kind using an active foaming technology to achieve lightweight, low density PLA parts. At around 230C this material will start foaming, increasing its volume by nearly 3 times. Users can decrease material flow by 65% to achieve lightweight parts, or use the expanding properties to effectively reduce print time by using big layer heights or single extra thick perimeters.

“ColorFabb came up with something really special and in my opinion a real game changer.”  – Bart Tangermann

Read Bart’s review of LW-PLA here.

Decreasing flow means using less filament. Therefore users can expect to print 2-3 times more parts using LW-PLA compared to a regular PLA spool. LW-PLA prints in a fantastic matte looking surface finish and is very easy to post process. Any oozing or stringing artifacts rub right off and the surface is easily sanded for a smooth finish.

LW-PLA is available in Black and Natural and is available now. We ship daily, worldwide and from stock.

“We need challenging materials, we need to work with or find ways around the limitations and allow more people to experiment with exciting developments like this foaming PLA.” – Richard Horne

Read Richard’s review of LW-PLA here.

 

Machine clamp

As we have seen before, 3D printing can be used in many production companies to create machine clamps. By using the right filament (and printer) it is easier, faster and cheaper than ever to optimize a production line so it suits your needs. Whereas 3D printing already has proven itself to shorten the prototype stage during product development, in production it can also bring down time to market and costs, while also adding more flexibility in the process.

This machine clamp was designed by our colorFabb team as a demonstrator during the recent Brabantse Metaaldagen, a tradeshow for the metal industry where we had a stand to demonstrate the added value of FDM/FFF 3D printing for various industries.

The clamp was printed on the Ultimaker 2+ using our PA-CF Low Warp with 100% infill. Print settings:

  • Printing temperature: 260C
  • Print speed: 35mm/s
  • Heated bed: –

We printed with a 0.2mm layer height.

Check out our handy tutorial How to Print with PA-CF Low Warp!

About PA-CF Low Warp

PA-CF Low Warp was launched a little over a year ago. It is a one of a kind polyamide formulation with the ability to print nearly warp free on non heated buildplatforms. PA-CF Low Warp excels in tensile and impact strength and allows continues use at 120°C while retaining sufficient mechanical properties.

The material can be printed on desktop FFF 3D printers, which have a temperature range of at least 260°C on the hot-end and the ability to mount an abrasive resistant nozzle. The formulation has been modified to reduce uptake of moisture and it also takes about 4 times longer to reach the saturation point compared to unmodified PA6. This makes PA-CF Low Warp less affected by moisture then most other nylon filaments available in the market.

 

 

The material shows good results when printed at ambient temperature, or cold bed. The advised processing temperature for this material is set between 260C and 280C. You can find more information about the printability of PA-CF Low Warp on our dedicated landing page.

A special point of attention is the abrasive nature of the carbon fibers. In general these fibers will accelerate the nozzle-wear of brass nozzles, much faster than unfilled filaments. ColorFabb recommends to using wear resistant nozzles, such as E3D hardened steel nozzle or Olsson Ruby nozzle.

PA-CF Low Warp is available now and ships on spools containing either 700gr of 2kg of filament. Click here to go directly to our webshop.

Light Weight Drone Parts

With our brand new lightweight PLA, LW-PLA, we offer a filament which is ideally suited for prints where weight matters. Drone enthusiasts have embraced 3D printing a long time ago. Replacement parts and customisation are easier than ever when reparing or enhancing ones drone. However, weight is always an issue with drones and with LW-PLA we offer a solution to reduce this with up to 65%!

Design by TheShortCrayon / link

We have printed the 82mm ducted brushless frame by TheShortCrayon for the 82mm Inductrix-style Brushless Quad with both PLA Economy and LW-PLA as a comparison. PLA Economy was printed with standard PLA settings. For the LW-PLA we use the following settings:

  • 0.2mm layer height
  • 245C nozzle temperature
  • 50C bed temperature
  • Printed with 38% flow

As you can see one reduces the weight significantly from 31 to 12 grams for this printed part!

Learn how to print with LW-PLA in our handy tutorial!

Micro FPV drones are all about power and performance. Reducing weight increases flight time and overall performance, which is why LW-PLA is an ideal candidate as a go-to filament.

LW-PLA is the first filament of its kind using an active foaming technology to achieve lightweight, low density PLA parts. At around 230C this material will start foaming, increasing its volume by nearly 3 times. Users can decrease material flow by 65% to achieve light weight parts, or use the expanding properties to effectively reduce print time by using big layer heights or single extra thick perimeters.

Decreasing flow means using less filament. Therefore users can expect to print 2-3 times more parts using LW-PLA compared to a regular PLA spool. LW-PLA prints in a fantastic matte looking surface finish and is very easy to post process. Any oozing or stringing artifacts rub right off and the surface is easily sanded for a smooth finish.

LW-PLA is available in Black and Natural and is available now. We ship daily, worldwide and from stock.

 

“We need challenging materials, we need to work with or find ways around the limitations and allow more people to experiment with exciting developments like this foaming PLA.” – Richard Horne, aka RichRap3D

Read Richard’s review of LW-PLA here.