Lyman Filament Extruder v3 Manual

LYMAN
FILAMENT EXTRUDER V3
FABRICATION & OPERATION MANUAL
DESKTOP FILAMENT EXTRUDING SYSTEM – 9/2/13
There will be some errors and omissions, as there always are.
First watch the video on YouTube, read and study the entire Manual
as well as all the comments on Thingiverse of two prior versions,
then you may contact me at the email below.
Changes, additions and corrections are welcome as I consider this
still as a work in progress.
Contact:
hlyman@comcast.net
CREDITS:
Jay Morgan – American Plastic Profiles

See the video on YouTube
http://www.americanplasticprofiles.com/
Lyman Filament Extruder V3 Video:

Johnny Russell – Ultimachine
https://ultimachine.com http://www.youtube.com/watch?v=p_E7crY9wfg
Jeff Moe – Aleph Objects, Inc
http://www.lulzbot.com/
Charlene Angle– Dimension Engineering, LLC

http://www.dimensionengineering.com/
Zach Kaplan—Inventables, Inc

https://www.inventables.com/
The Lyman Filament Extruder V3 is an open source product licensed under
http://creativecommons.org/licenses/by-sa/3.0/
SABERTOOTH & KANGAROO
TEMP READINGS
This micro processor is mounted on the control
Nozzle— 175C
panel for easy access to the Kangaroo motor Flange— 65C
pots, wherein the puller motor can be adjusted Insulator— 36C
to sync with the extruder motor. Hopper Base—34C
The motors have to be tuned to the processor Water— 35C
so it is important to follow the instructions.
carefully.
WATER COOLING TANK

I cut the Plexiglas tank parts on a laser en-
graver cutter, (complements of Inventables). A
work in progress is a tank with 1/4” Plexiglas,
wherein a resizing die with be included. See
part drawings. Water temperature never ex-
ceeded 35 degrees Celsius.
FILAMENT EXTRUDER
This turned out to be a work of art. Eliminated a whole bunch of hardware. One
simple hopper and motor mount. It is printed with extruded ABS Lyman filament.
PULLER ROLLER ASSEMBLY Note the auger is surrounded with pellets when filled. The Extruder is not attached
3D printed these parts, combined motor mount to the base so it can be tipped to empty the pellets. I tried several flexible couplers
with roller housing for easy setup. The idler and this is the one I used. On the first assembly, alignment was good. The coupler
roller cradle has a 3/8” hole in the top where a is drilled and taped for two set screws to engage the flat part of the shafts, as the
wood dowel stud is inserted to hold the bottom tightening screws that comes with the coupler won’t hold under torque. The Plexi-
of the spring in place. The top 3/8” bolt holds glas hopper allows for visual reference of the pellet level and is removable. The
the top of the spring in place. The bearing and lead weight maintains a steady pressure on the pellets. It takes two filling of the
motor holes have to be dressed for a snug fit. hopper to extrude enough filament to fill a 1kg spool.
LEVEL WIND REEL W/COUNTER.

The handle is removed and the spool is filled
with masking tape to a diameter that gave a
correct count on the counter. The strip of
sandpaper is used to help feed the filament
through under the spool. In watching the
video you will see why cooling tank and the
reel are not attached to the base.
SPOOL WINDUP ASSEMBLY

This is the same design as my original Spool
Winder as seen on YouTube.
It can accommodate different size spools. As
there are many size spools you will need
different size spool collars. The stl file I have
included is only one size, so design your own.
EXPLAMATION OF CREDITS
Jay Morgan is the Vice President of American Plastic Profiles. After he read articles about my wining
the Desktop Factory Competition, he gave me a call. He told me he was going to build an extruder similar
to mine for extruding Silicone. Over the last six months he has become a very good friend and has given
me many of the features included in Version 3, which includes water cooler, micro processor, nozzle ori-
fice size, puller roller and others.
Johnny Russell is with Ultimachine, a company that I have purchased many parts from for 3D printing.
He was so gracious in supplying me with motors and giving me other help. Unfortunately the motors are
not used in the Extruder.
Jeff Moe is the owner of Aleph Objects, another company I purchase 3D printer parts from. He has
helped my greatly in my early days of 3D printing and never hesitated to answer a question or to help me
solve a problem. I believe he will soon be offering Extruders for sale.
Charlene Angle is with Dimension Engineering Company which furnished the micro processor for the
extruder. She has spent hours, days and weeks helping me to accomplish making the system work. This
processor procedure was new to me, but she never gave up when I was ready to and she kept prodding me
on. Watch her video on there website.
Zach Kaplan is the owner of Inventables who developed the Desktop Factory Competition, he is listed
last but not least. As I am living on retirement income at 84, winning the competition helped make this
invention possible. It took two submissions to get his attention and then he spent considerable time in the
approval of the invention. One morning early in March I got a phone call from Zach, that my extruder
passed all the test and is the winner. It was and is a very good feeling. Zach came to Seattle and my wife
and I met him and had dinner, he is an amassing young man.
As this is probably the last invention I will accomplish, I am pleased to share it with the World.
HELLO WORLD
TOOLS USED NOTES:
1. Table Saw Please note that in the Bill of Materials (BOM) the costs shown in many cases are estimated. Many
parts have to be purchased in quantities greater than is needed. Also different products can be used.
2. Band Saw
Listed is a BOM for just the Extruder alone with the required electronics. It requires a lot less time
3. 3D Printer and materials from prior versions. The motor will not need and encoder.
4. Laser Engraver Cutter * I have cross referenced the drawings and part numbers for ease of finding, however don’t be sur-
prised if errors are found.
5. Drill Press
6. Grinder I am not yet satisfied with the filament diameter tolerances. The diameter of 1.75mm filament is
greater than I would like, however I have extruded now over 8 spools of filament and have been
7. CNC Router * using it in my Printer. I have not yet extruded 3mm filament, but will try shortly.
8. Welder * My first two versions of the Lyman Filament Extruder extruded at about 8” of filament per minute at
212 degree Celsius. I learned later that I was using injection molding filament, not extrusion grade.
9. Cut Off Saw * Also they had a less powerful motor.
10. Sander * Using the correct grade filament Version 3 is extruding at 30” per minute 1.75mm filament at 175 C.
The counter showed about 1100 ft per 1 kg spool, 7+ hours. I have visions of getting 48” per min-
11. Thread Tap Dies ute. The diameter is varying from 1.65 to 1.85mm ,which however seems to print just fine.
12. Soldering Iron
The theory of the system is to have the puller rollers pulling the filament from the extruder with mo-
13. Hot Melt Gun tors sync rate adjusted to obtain the correct diameter. Thus, the extruder nozzle orifice is 1.5 times
larger than the desired diameter.
14. Dremel
Four variables control the filament diameter:
15. Metal Lathe * 1. Nozzle orifice diameter (adjusted with a drill bit)
2. Nozzle temperature (adjusted with PID).
16. Lead Electric Melter * 3. Motors sync (adjusted with Kangaroo pots).
4. Extruding speed (adjusted with manual pot).
17. Misc Hand Tools
As this is still a work in progress, I plan on adjusting all four variables and installing a resizing die at
* All these tools may not be needed as some functions the inlet (left side) of the water tank to improve the tolerances.
can be done by hand or subbed out and engraving is
optional. Hope you enjoy the manual.
Good luck, Hugh Lyman

BOM ‐ LYMAN FILAMENT EXTRUDER V3 (sorted by Description)
Unit Est Total Est SUPPLIER PART # or ID NOTES: These suppliers are only suggestions and better pricing
Part # Dwg # DESCRIPTION QTY UNIT SUPPLIER
Price Price where I got it may be found elsewhere
71 A11 Aluminum Flat Bar 1/8"x 1/2" 1 FT $0.43 $0.43 OnLine Metals

45 A07 Auger Bit 5/8"X 18 1 EA $26.38 $26.38 2878A15 McMaster Carr
12 A07 Band Heater 1" 1 EA $24.00 $24.00 G2156542 Zoro Tools Needs a little enlarging by prying open at little
88 A12 Battery 24V NMH 1 EA $10.08 $10.08 ebatteryoutlet eBay I made with rechargeable 1.2V NMH batteries
66 A10 Bearing Ball Flanged 1/4" 2 EA $5.00 $10.00 6383K213 McMaster Carr
21 A07 & A08 Bearing Thrust 3/8" 1 EA $2.47 $2.47 6655K15 McMaster Carr
34 A08 Bearings Ball 3/8" 4 EA $4.50 $18.00 6383K16 McMaster Carr
14 A07 Black Iron Nipple 1/2" NPT x 3.5" 1 EA $1.28 $1.28 44615K554 McMaster Carr
13 A07 Black Pipe Coupling 1/2"NPT 1 EA $1.00 $1.00 46685K264 McMaster Carr OD Diameter should be 1.06" for 1"heat band
36 A08 Bolt 3/8"x 1" 1 EA $0.50 $0.50 True Value Hardware On hand
11 A07 Brass Plug 1/2" NPT 1 EA $3.69 $3.69 50785K337 McMaster Carr
46 A09 Brass Plug 142" NPT 1 EA $2.00 $2.00 Fastenal Work in Progress
26 A07 Bushing Brass Flanged 3/8" 1 EA $0.70 $0.70 6338K414 McMaster Carr
24 A07 & A08 Coupler Flexible 6.35m x 10mm 2 EA $8.00 $16.00 giorgio11185 eBay
10 A04 Funnel 45 FT $0.04 $1.80 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface
84 A12 Fuse Holder & Fuse 5A 1 EA $2.00 $2.00 071‐510 Parts Express Optional
23 A07 & A08 Gear Motor w/Encoder 2 EA $79.00 $158.00 TD‐044‐013 SuperDroll Robotics Included Pull‐up Board & Hookup Kit
3 A06 Hardboard 1/4 2 SF $1.00 $2.00 Home Depot Ön hand
19 A07 Hopper & Motor Base 33 FT $0.04 $1.32 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface
18 A07 Insulation Bd Rigid 1/2 1 SF $12.80 $12.80 9353K31 McMaster Carr More than you will need
79 A12 Kangaroo add‐on 1 EA $24.00 $24.00 Kangaroo x2 Dimension Engineering Check with Supplier for additional parts needed
90 A12 Knob for Pots 2 EA $0.04 $0.08 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface
69 A10 Latex Tube 3/4" & 1/2" dia 1 LOT $5.00 $5.00 808 & 1608 Latex‐Tubing.com Purchased 12" of each
81 A12 LED Green Small 2 EA $1.00 $2.00 Parts Express Optional ‐ goes on 110V Circuits ‐ On hand
76 A12 LED Red Small 2 EA $1.00 $2.00 Parts Express Optional ‐ go on 24V Circuits
72 A11 Level Wind Fishing Reel 1 EA $50.00 $50.00 eBay Optional ‐ I used an old one with a counter I had on hand
1 A05 MDF BOARD 1/2" 3.5 SF $1.00 $3.50 Home Depot Use what ever you have, plywood etc.
4 A06 MDF BOARD 1/2" 2 SF $1.00 $2.00 Home Depot On hand All can be cut from I piece 24"x 48"
5 A06 MDF BOARD 1/2" 1 SF $1.00 $1.00 Home Depot On hand
50 A10 MDF BOARD 1/2" 0.6 SF $1.00 $0.60 Home Depot On hand
8 A04 MDF BOARD 3/4", 1/4 1 SF $1.50 $1.50 Home Depot Use what ever you have, plywood etc.
54 A10 Mini Gear Motor 1 EA $10.00 $10.00 hjb0805 eBay This 12V so need a voltage regulator
Page 4
62 A10 Motor Arm for Winder Motor 25 FT $0.04 $1.00 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

65 A10 Nut Hex 1/4" NyLok 1 EA $0.15 $0.15 97135A210 McMaster Carr You will buy 25 ea. or get them at hardware store
15 A07 Nut Hex M4 NyLok 4 EA $0.11 $0.44 40147 Fastenal
64 A10 Nuts Hex 1/4" 4 EA $0.10 $0.40 True Value Hardware On hand
80 A12 PID 1 EA $27.00 $27.00 mambate eBay
68 A10 Plastic Spool 1 EA $0.00 $0.00 Everybody On Hand
9 A04 Plexiglas 1/8" 0.2 SF $5.05 $1.01 24161‐01 Inventables.com
35 A08 Plexiglas 1/8" 1 SF $5.05 $5.05 24161‐01 Inventables.com
75 A12 Potentiometers 5K 2 EA $16.00 $32.00 882‐MW22B‐3‐5K Mouser
86 A12 Power Supply 24V 1 EA $24.00 $24.00 hi‐etech eBay
47 A09 PTFE 1/4" DIA 1 EA $2.00 $2.00 McMaster Carr Work in Progress
42 A09 Pump Aquarium 110V 1 EA $6.84 $6.84 cll_petsupplies eBay
82 A12 Resistors 1M ohms 2 EA $1.00 $2.00 Pats Express Optional ‐ goes on 110V Circuits ‐ On hand
77 A12 Resistors 320 ohms 2 EA $0.50 $1.00 Parts Express Optional ‐ goes on 110V Circuits ‐ On hand
39 A08 Rod Steel 3/8"x 3.5" 1 EA $1.00 $1.00 8920K135 McMaster Carr
33 A08 Roller & Motor Base 203 FT $0.04 $8.12 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface
38 A08 Roller Idle Bracket 59 FT $0.04 $2.36 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface
2 A05 Rubber Bumper Feet 4 EA $0.50 $2.00 True Value Hardware
78 A12 Sabertooth 2X12 1 EA $80.00 $80.00 Sabertooth 2X12 Dimension Engineering Check with Supplier for additional parts needed
87 A12 Sabertooth Standoff 15 FT $0.04 $0.60 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface
44 A09 Scrap Block 1 EA $0.01 $0.01 HML (me) On Hand
56 A10 Screw Cap M3 x 10mm 2 EA $0.12 $0.23 Fastenal
25 A07 & A08 Screw Cap M3 x 15mm 8 EA $0.20 $1.60 Fastenal
40 A08 Screw PHSM #4 x 1/2" 2 EA $0.05 $0.10 True Value Hardware On hand
6 A06 & A10 Screw PHSM #6 x 1" 10 EA $0.05 $0.50 True Value Hardware On hand
7 A06 & A11 Screw PHSM #6 x 3/4" 8 EA $0.05 $0.40 True Value Hardware On hand

Page 5
57 A10 Screw PHSM #8 x 1" 1 EA $0.05 $0.05 True Value Hardware On hand
85 A12 Solid State Relay 1 EA $6.00 $6.00 eBay
58 A10 Spool Collar 17 FT $0.04 $0.68 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface
37 A08 Spring 1/2"x 1" 1 EA $1.50 $1.50 True Value Hardware Compression type
67 A10 Spring 1/4"x 2" 1 EA $1.50 $1.50 True Value Hardware Extension type
17 A07 Steel Flat (Flange) 1/4" 1 EA $20.00 $20.00 OnLine Metals On hand
83 A12 Switch Master Off On 1 EA $2.29 $2.29 sseariver2009 eBay Optional
74 A12 Switch SPST 5 EA $0.95 $4.75 12216 SW MAJPA
30 A07 Thermocouple Type K 1 EA $1.24 $1.24 tinxi‐clothes eBay

63 A10 Threaded Rod 1/4" 1 FT $1.00 $1.00 Home Depot You may have to buy 3 feet
43 A09 Tubing Flexible 1/4" 1 FT $1.88 $1.88 5792K35 McMaster Carr You will buy 5 ft @ $1.88 per ft
32 A08 Urethane Drive Rollers 2 EA $30.00 $60.00 2475K61 McMaster Carr
91 A12 Variable Voltage Control 1 EA $5.00 $5.00 e‐worldseller eBay
27 A07 Washer Flat 3/8" 1 EA $0.10 $0.10 True Value Hardware
22 A07 & A08 Washer Flat M3 8 EA $0.02 $0.16 40352 Fastenal
55 A10 Washer Flat M3 2 EA $0.02 $0.04 40352 Fastenal
29 A07 Washers Phenolic 1/8" 1 EA $14.50 $14.50 8710K537 McMaster Carr 6x6 sheet
48 not used
49 not used
73 not used
Contingencies, TTT, Findings 1 LOT $80.00 $80.00 estimated Items not listed or missed, connectors, zip ties, and etc.
SUB TOTAL COST $806.54
ESTIMATED FRT IN @ 10% $80.65
TOTAL COST $887.19
Page 6
BOM ‐ LYMAN FILAMENT EXTRUDER V3 (sorted by Part #)

Page 7

48 not used
49 not used
Page 8
73 not used
TOTAL COST $888.14
Page 9
BOM ‐ LYMAN FILAMENT EXTRUDER V3 (sorted by Supplier)

Page 10

Page 11

48 not used
49 not used
73 not used
TOTAL COST $885.65
Page 12
BOM ‐ LYMAN FILAMENT EXTRUDER V3 ( Extruder only no wood parts)
Unit Est Total Est SUPPLIER PART # or NOTES: These suppliers are only suggestions and better pricing
Price Price ID where I got it may be found elsewhere

13 A07 Bearing Thrust 3/8" 1 EA $2.47 $2.47 6655K15 McMaster Carr
15 A07 Gear Motor 1 EA $60.00 $60.00 TD‐044‐013 SuperDroll Robotics
16 A07 Coupler Flexible 6.35m x 10mm 1 EA $8.00 $8.00 giorgio11185 eBay
TOTAL COST $253.54
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LYMAN

Jay Morgan – American Plastic Profiles

Lyman Filament Extruder V3 Video:

Charlene Angle– Dimension Engineering, LLC

Zach Kaplan—Inventables, Inc

The Lyman Filament Extruder V3 is an open source product licensed under

WATER COOLING TANK

LEVEL WIND REEL W/COUNTER.

SPOOL WINDUP ASSEMBLY

Good luck, Hugh Lyman

71 A11 Aluminum Flat Bar 1/8"x 1/2" 1 FT $0.43 $0.43 OnLine Metals

62 A10 Motor Arm for Winder Motor 25 FT $0.04 $1.00 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

47 A09 PTFE 1/4" DIA 1 EA $2.00 $2.00 McMaster Carr Work in Progress

42 A09 Pump Aquarium 110V 1 EA $6.84 $6.84 cll_petsupplies eBay

82 A12 Resistors 1M ohms 2 EA $1.00 $2.00 Pats Express Optional ‐ goes on 110V Circuits ‐ On hand

77 A12 Resistors 320 ohms 2 EA $0.50 $1.00 Parts Express Optional ‐ goes on 110V Circuits ‐ On hand

39 A08 Rod Steel 3/8"x 3.5" 1 EA $1.00 $1.00 8920K135 McMaster Carr

31 A08 Rod Steel 3/8"x 4.5" 1 EA $1.00 $1.00 8920K135 McMaster Carr

33 A08 Roller & Motor Base 203 FT $0.04 $8.12 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

38 A08 Roller Idle Bracket 59 FT $0.04 $2.36 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

2 A05 Rubber Bumper Feet 4 EA $0.50 $2.00 True Value Hardware

78 A12 Sabertooth 2X12 1 EA $80.00 $80.00 Sabertooth 2X12 Dimension Engineering Check with Supplier for additional parts needed

87 A12 Sabertooth Standoff 15 FT $0.04 $0.60 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

44 A09 Scrap Block 1 EA $0.01 $0.01 HML (me) On Hand

56 A10 Screw Cap M3 x 10mm 2 EA $0.12 $0.23 Fastenal

25 A07 & A08 Screw Cap M3 x 15mm 8 EA $0.20 $1.60 Fastenal

53 A10 Screw Cap M4 x 30mm 1 EA $0.20 $0.20 Fastenal

28 A07 Screw Cap M4 x 40mm 4 EA $0.25 $1.00 Fastenal

40 A08 Screw PHSM #4 x 1/2" 2 EA $0.05 $0.10 True Value Hardware On hand

6 A06 & A10 Screw PHSM #6 x 1" 10 EA $0.05 $0.50 True Value Hardware On hand

89 A12 Screw PHSM #4 x 1/2" 8 EA $0.03 $0.24 True Value Hardware On hand

7 A06 & A11 Screw PHSM #6 x 3/4" 8 EA $0.05 $0.40 True Value Hardware On hand

57 A10 Screw PHSM #8 x 1" 1 EA $0.05 $0.05 True Value Hardware On hand

20 A07 & A08 Screw PHSM #8 x 3/4" 8 EA $0.05 $0.40 True Value Hardware On hand

85 A12 Solid State Relay 1 EA $6.00 $6.00 eBay

58 A10 Spool Collar 17 FT $0.04 $0.68 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

61 A10 Spool Collar 17 FT $0.04 $0.68 1.75 Filament Filament Supplier Converted to FT from mm shown in Ponterface

37 A08 Spring 1/2"x 1" 1 EA $1.50 $1.50 True Value Hardware Compression type

67 A10 Spring 1/4"x 2" 1 EA $1.50 $1.50 True Value Hardware Extension type

17 A07 Steel Flat (Flange) 1/4" 1 EA $20.00 $20.00 OnLine Metals On hand

83 A12 Switch Master Off On 1 EA $2.29 $2.29 sseariver2009 eBay Optional

74 A12 Switch SPST 5 EA $0.95 $4.75 12216 SW MAJPA

30 A07 Thermocouple Type K 1 EA $1.24 $1.24 tinxi‐clothes eBay

1 A05 MDF BOARD 1/2" 3.5 SF $1.00 $3.50 Home Depot Use what ever you have, plywood etc.

37 A08 Spring 1/2"x 1" 1 EA $1.50 $2.36 True Value Hardware Compression type

78 A12 Sabertooth 2X12 1 EA $80.00 $80.00 Sabertooth 2X12 Dimension Engineering Check with Supplier for additional parts needed

3 A06 Hardboard 1/4 2 SF $1.00 $2.00 Home Depot Ön hand

82 A12 Resistors 1M ohms 2 EA $1.00 $2.00 Pats Express Optional ‐ goes on 110V Circuits ‐ On hand

1 A04 Plexiglas 1/8" 1 SF $5.05 $5.05 24161‐01 Inventables.com

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