To raft or not to raft?

When extruding HDPE onto foam board a raft needs to be laid down first to increase the anchorage at the corners to reduce curling. It becomes part of the object and has to be trimmed back to its outline with scissors or a knife. Now that I am extruding onto polypropylene cutting board I wondered if it was still necessary.

The temperature at which I lay down HDPE onto the cutting board is important. At 180°C it does not stick. At 200°C it sticks well but can be peeled off with the help of a penknife. Higher temperatures make it harder to remove and do more damage to the board.

Here are a couple of 15mm test cubes made directly onto the PP board without a raft :-



The one on the left had the first layer extruded at 200°C and subsequent layers at 240°C. As you can see it curled badly, particularly at one corner. The one on the right had its first layer extruded at 220°C. It looked promising but when I tried my standard warp test block the result was not good!



So it looks like the raft is here to stay. Here is an example :-



I lay down the raft at 4mm/s with a notional filament diameter of 1.1mm with the extruder head 1.3mm above the board. This is to get the filament as round as possible so that it doesn't form a solid weld. In actual fact, gravity causes it to slump to about 0.9mm high and spread to 1.3mm wide. The oval area calculation would give 1.34mm and a pitch of 1.3mm is sufficient to get adjacent filaments to stick together. My rationale for making the raft as thick as possible in one layer was to make it strong without taking too much time. It probably does not need to be as strong now that it binds to the PP.

I put the raft down at 200°C, then I do the first layer of the object at 240°C with the fan off to ensure it welds to the raft and then subsequent layers at 240°C with the fan on.

I calculate the amount the raft overlaps the object with this completely arbitrary function :-

def overlap(x):
  return x + 10 + 10.0 * (x - 20) / 80

I halved the overlap when I went from foam board to polypropylene.

Cutting corners

When making solid blocks with 0.5mm HDPE filament I noticed that the corners are not very accurate. The right hand edge of the 20mm cube below shows this effect at its worst :-



The problem is that, although the machine makes a perfect right angle, the filament appears to have a minimum bend radius and so cuts the corner. The amount it cuts the corner seems to vary from layer to layer giving rise to the rough edge.

I think the variation is due to the fact that my extruder spindle is a bit off centre. This causes the torque to go up and down as it rotates, which causes the flexible drive cable to wind up and run down again. This causes speed variations despite the fact that the motor speed is well regulated. At some point I will get rid of the flexible drive.

I expect the fact that I am stretching the filament doesn't help with the corner cutting. I improved it a lot by slowing down the drawing of the outline to 4mm/s and leaving the infill at 16mm/s. Here is the result :-



Still not perfect, another thing to try would be to recognise that there is a minimum corner radius and make the nozzle follow an arc of that radius around the corner. At least that way it might be more uniform.

Here is a close up of the top face taken with a scanner:-



As it goes round the corner the filament has an external radius of about 1.5mm and an internal radius of 0.9mm. As it is 0.6mm wide that is probably not bad. You can also see that the zigzag infill sometimes ends a bit short of the edge, probably also due to corner cutting.

To get sharper corners I expect I need to use a nozzle with a smaller hole, so that the filament can be fine without having to be stretched, but that has the disadvantage of slowing down the extrusion rate for a given pressure.

Warped

Having got an idea of the HDPE warping for thin walled open boxes, I decided to start investigating solid shapes. I made a solid block 40 x 10 x 20mm to compare with the open boxes of the same dimensions.



Obviously there are many ways to fill the interior so I started with the simplest, just alternate layers of horizontal and vertical zigzags. HydraRaptor seems quite happy extruding 0.5mm diameter filament at 16 mm / second. If extruded into free air it would actually be 1mm at 4mm/s, but that is too course, so I move the head at 16mm/s which stretches it.

From trial and error I have found that a good layer height to use is 0.8 times the notional filament diameter. If it is more, then as the lower layers shrink, the nozzle rises faster than the object and a gap develops. Once that happens the filament squirms about and does not follow the path of the nozzle accurately.

So the extruded filament is constrained to 0.4mm high. Measurements show the width to be about 0.6mm. Incidentally, if it squashed to a perfect ellipse with a height of 0.4mm then it would be 0.625mm wide to have the same area as a 0.5mm circle. I extrude the zigzag with a pitch of 0.6mm so that adjacent filaments touch, but it means the object is not actually completely solid. The space occupied by each filament is a rectangular channel 0.4 x 0.6 = 0.24mm² but the cross sectional area of the plastic is π x 0.25² = 0.20mm², so about 18% is air. I confirmed this by weighing the block. It weighs 6.5g but if it was solid HDPE then 8ml would weight about 8g. It takes about 45 minutes to make the object including laying a raft.

Before I tried it, I always imagined the amount of plastic deposited would have to exactly match the volume of the extruded object otherwise it would sag or bulge. I could never understand how FDM worked reliably. Now I know that the volume can be a bit less and the difference is made up by air. That means the amount of plastic deposited is actually not that critical, which is why RepRap can get away with an open loop extruder.

I measured the warping with the three nail jig that I showed in the last post. The thin walled box is warped 0.44mm and the solid box has warped 0.87mm so that answers the question whether solid objects warp more or less. Note that the thin walled box is made with 1mm filament because 0.5mm filament is too thin to be self supporting.

I expect I can make a less warped block by extruding a thick base and then a less dense infill above that. Something else to try.

It is amazing how strong 10mm thick HDPE is. You don't often get to see plastics in that form. Most end products have optimised strength against cost by having thin walls and ribs etc.