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Electronhacks made this video to show production process of the 3d printed fan duct. However it is also excellent demonstration of friction welding plastic with filament inserted into Dremel. The friction produced makes a strong welded bond.



Video by ElectronHacks

























Here are 3d printable rivets that you can use:

http://diy3dprinting.blogspot.com/2014/01/3d-printed-rivets-for-friction-welding.html

Here is another post about DIY ultrasonic and soldering iron plastic welding:

http://diy3dprinting.blogspot.com/2012/12/diy-ultrasonic-plastic-welding.html

Update:

here is a video with same friction welding technique with PLA plastic.



Update 2:

Here is a video about how PLA 3d printed part is cut with hot wire cutter. The cutting looks easy and precise. Hot wire cutter are usually used to cut various types of  foam and are easy to make. Looks like they can cut some PLA plastics, I wonder what would they do with ABS ...




Here is a simple schematics of a DIY hot wire cutter:
















Video source:

https://www.youtube.com/user/DistractedArchitect?feature=watch

Louis Cordoba designed and 3d printed custom nebulizer mask for his asthmatic child.  Regular mask was too big for his baby boy so he made a smaller one with better fit so that child could be administered with correct dosage of medicine. It took 3 hours to print using 20 grams of PLA.












.stl files downloadable at:

https://www.youmagine.com/designs/mask-for-babies

Update:

here is 3d printable asthma inhaler:

http://diy3dprinting.blogspot.com/2013/12/3d-printable-asthma-inhaler.html

PLA and BAS are most used materials in 3d printing. If we used PLA as support meterial, how can it be removed from ABS without damage to ABS? PLA can be dissolved with caustic soda  in ultrasonic tank.

Bertho Boman experimented with various concentrations and presented results on his blog:

This time I tested several different plastic types and varying strength Sodium Hydroxide.
1.0 Molar: 40g per liter water
1.8 Molar: 72g per liter water (same as the video)
3 Molar: 120g per liter water
6 Molar: 240g per liter water

Test Result:
After 5 hours in the ultrasonic tank @ 60°C there was no visual effect or surface hardness change evaluating the samples under a microscope of the different plastic types except the PLA.

http://www.vinland.com/blog/?p=162




































Extensive details and experiments with other methods and how to dissolve PLA fast when no other material is involved:

http://www.vinland.com/blog/?p=68#more-68


Here is video showing the process with professional ultrasonic tank and caustic soda (sodium hydroxide) that takes 3 hours to remove PLA support material from ABS part. 217 grams is added to 3 liters of water heated at 60C.
Ultrasonic tank used in the video is priced around 1300 USD, but it can be found much cheaper at some 300 USD.




They talk about dissolving PLA in .stl podcast (great podcast btw):



RepRap forums discussion:

http://forums.reprap.org/read.php?1,153508,199753

Proto Pasta has some new filaments with enhanced properties then regular PLA / ABS.



Video from their Kickstarter:

Proto Pasta offers:

Carbon Fiber Reinforced PLA

Proto-Pasta High Temperature PLA is made from a custom compound consisting of mineral filled impact modified PLA with a nucleating agent to help promote crystallization. Crystallization after printing is what gives this material added heat resistance. To fully realize this advantage, parts must be soaked in hot water or an oven after printing at 60C-80C for 3-5 minutes. This crystallizes the material and makes it much more heat resistant. It does not require a heated bed to print well, but this may help crystallize the material after printing and make oven soaking unnecessary for some parts. High Temperature PLA is a glossy off white, or very light gray. Printed parts look good and have slightly more texture than standard PLA. This material is not translucent like standard PLA.
We have had good results printing at 190C-210C using a .5mm nozzle and direct-drive spring loaded pinch-roll style extrusion head.
Layer adhesion is good and the material has low warpage.

Things ain't gonna tie themselves together without some outside help. :-) Here is a great project by Rich Olson done in soft PLA.









Thingiverse page (you can use Thingiverse custimizer to change sizes)

http://www.thingiverse.com/thing:178234

Olson's blog and more details:

http://nothinglabs.blogspot.com/2013/11/3d-printed-hook-loop-fasteners.html

He has great tips post on how to print with various filament types including elastic PLA:

http://nothinglabs.blogspot.com/2013/09/filament-roundup-3d-printing-in-all.html

Richard narrates his experience with 3d printing puzzle pieces. He puts his build plate into container filled with water to easily remove PLA pieces.



Source:

http://www.youtube.com/user/microcubology?feature=watch

There are more filaments from various materials available for 3d printing then just simple PLA and ABS. Here are some links on news related to filaments ...

Excellent roundup post by NothingLabs on various filaments, how to print with them and their properties:

http://nothinglabs.blogspot.com/2013/09/filament-roundup-3d-printing-in-all.html

Here is his detailed presentation from google docs: http://tinyurl.com/kq3sbjd

Color changing and magnetic metal infused 3d printing filaments 

http://printm3d.com/filaments/

New flexible material - Filaflex

http://recreus.com/

Hackaday video from Maker Faire 2013:

Extensive test of soft PLA (FlexPLA):

http://algorithmicart.wordpress.com/2013/08/22/3d-printing-with-flexible-materials-flexpla-tests/

Detailed videos of design and build process of new DIY RepRap based 3d printer project: ProtoForge. It looks very high quality built and well designed printer.






From video description:

These are the key features:
Build volume: 300x300x300 mm³ with heated bed up to 110 °C
Material: PLA, ABS, PVA
Dual Print head: 200-300g
Controller: Arduino Mega + Ramps 1.4
Extruder System: bowden extruder with feedrate measurement and control
Housing: rigid aluminum frame and pmma (plexiglas) panels

Main goals:

• big build volume
• as fast as possible
• print quality as good as possible
• PVA support material

Video source: