Re: [DIYbio] Manufacturing Gel Boxes inexpensively

On 05/18/2015 12:55 PM, Nathan McCorkle wrote:
> vacuum-forming would be a good way
+1

1. Instead of starting with sheet, and using big heaters, maybe
3D print, (fused plastic deposition) onto a mold, so one side would be smooth
even for fast flow rates with big nozzles. That would still have a big draft angle like vacuum formed parts
need, but not the big heaters. An extruder nozzle that is long-skinny would be needed for clearing the draft angle
if left vertical, or need more complex movement to extrude along a toolpath inside a tray
by tilting so the fat heater nozzle could clear the part. Long-skinny could freeze and clog, but
not if you keep your speed up... I'd go for speed and a quick change hot end nose that is narrow-deep,
rather than bog down in 3D toolpath design.

2. make your own filament by the tens of pounds from cheap-scrap/your-own-scrap
with setup like this: http://www.soliforum.com/topic/8876/pet-tglase-regrind

I"m thinking of getting one of these extruders to make filament even though I
don't want a FDM machine yet -- there are many FDM machine operators for hire in town here.

3. Or, if you want the usual batch sizes of 1000's, hire a standard vacuum former and use sheet
plastic as your input. I've been reading books on vac forming lately and it's still big, hot,
and for pretty thin sheet mostly.

4. Instead, what I' studying now is vac-from from regrind scrap -- using ABS as the
tooling to vac form against, and starting a product vac-form "blank" with
a "rough" FDM print via a 1.5mm or 2mm nozzle. Then you make a heating setup of ceramic IR heaters
surrounding your vac-form "blank", (mine are cylindric mostly, but shallow trays could work well also),
and use some genuine teflon fingers for it to sit on without sticking and take the heat like teflon,
and when the vac-form "blank" is "rubbery" move it to the vac form mold and seal and suck.


Proof of concept of using ABS as mold material: http://www.stratasys.com/resources/case-studies/commercial-products/whale
https://www.youtube.com/watch?v=TOKj6CsZ92M

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