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Thomas Sanladerer designed , printed and tested this filament diameter sensor. It could bi used on filament making extruders as a control sensor, or in 3d printers to get better printout results. The work on it is in progress, further accuracy improvements are needed but the current results look promising.































Files can be found at:

https://www.youmagine.com/designs/filament-diameter-sensor


From project description:

This is a proof-of-concept filament diameter sensor, currently intended for an extruder making filament. The filament centerline is 90mm above the mounting surface.
It picks up the filament's diameter between two bearings, amplifies it via the lever by a factor of 3.6, which moves a magnet in front of the hall sensor.
The hall sensor's depth is adjustable and is locked into place via the M3 bolt. Bend the hall sensor's leads 90° to the back and place the sensor in recessed spot. Lead the wires out to the front.
The 6x2mm magnet goes into the matching hole in the lever. The second hole intended for a ballpen spring, which is not needed in most use cases.
For testing, upload the included sketch to an Arduino, connect the hall sensor to 5V, ground and hook the signal pin up to A1 on the Arduino. Connect via serial at 115200 baud, it will start spitting out two values each line, the first one is the smoothed ADC value, the second one the calculated diameter. To calibrate, insert a test object with the maximum diameter you want to measure between the bearings and move the hall sensor carriage until the ADC value just reaches a maximum. Lock the carriage in place and use that value along with the diameter of the object as the last entry in the Arduino's lookup table. Insert two (or more, if you increased NUMTEMPS) more objects of varying sizes (for example the shafts of drill bits) and fill out the lookup table. Use the idle position without anything inserted for the zero-diameter position.
Support might be required for the files as they contain 30° overhangs. If you use Slic3r, you're better off with no support material.

From project description:

Extruding natural ABS at 18"/min. The guide limit on the left isn't quite far enough to the edge. The loop seems fairly unstable seen at high speed, but the tolerance was still within .05mm. I fixed the loop near the end by keeping the filament from getting pushed back past the nozzle. As long as the filament leaves the nozzle at a constant angle for the time it takes to get from the extruder to the winder, the shape of the loop will stay consistent for the rest of the job.

Detailed information and downloads:

http://www.thingiverse.com/thing:174383

http://solidoodletips.wordpress.com/




























Here is older v2:

http://diy3dprinting.blogspot.com/2013/08/filament-winder-v2.html


Source:

http://www.youtube.com/channel/UCIdXEJdOG4_JWPI7LRzs-jA?feature=watch

X-winder wraps carbon fiber with epoxy on rotating object. It lowers the price of carbon tubes and elements by up to 80% compared to market prices.

When you look at it from broader perspective it is a from of 3d printer which prints with carbon fiber, it just needs to be upgraded and developed to be able to print non-rotating shapes with full x/y/z movement or at least to reinforce ABS/PLA parts with carbon fiber applied on their surface.

There were similar solutions on the beginning of DIY 3d printing machines development like this 3d printer which printed silicone on rotating tube:

http://diy3dprinting.blogspot.com/2013/10/from-diy-3d-printing-history-1-silicone.html

There were successful applications of epoxy surface glued Kevlar and carbon fibers on regular ABS/PLA 3d printed parts which gave them amazing strength:

http://diy3dprinting.blogspot.com/2013/06/carbon-and-kevlar-fiber-reinforced-3d.html

For next level in carbon printing we need to bring those concepts in a single machine.
Hopefully there will be someone to develop this idea further.






X-winder kickstarter:

http://www.kickstarter.com/projects/1157143472/x-winder-the-worlds-first-desktop-filament-winder

X-winder home page:

http://xwinder.com/

X-winder PDF brochure:

http://www.xwinder.com/X-Winder_TriFold_Brochure.pdf

X-winder technical specifications for standard 4 foot model and expanded 8 foot model

By Ian Johnson





Here is the first version:

http://diy3dprinting.blogspot.com/2013/05/guided-filament-winder.html

Update:

here is v3:

http://diy3dprinting.blogspot.com/2013/11/new-filament-winder-winder-v3.html