3D printing with standard plastic pellets

3D printers operating on the fused layer deposition (FLD) principle are fed with plastic filament to generate objects. Butas is the case with the traditional 2D ink jet printer, cartridges tend to be costly. Now, a Columbus-based startup is planning to transform the status quo with a new type of printer that can operate using standard plastic pellets fed from a continuously fillable hopper.

The David 3D printer from Sculptify (Columbus, OH) utilizes fused layer extrusion (FLEX) technology to create objects from a wide range of pelletized materials including polylactide (PLA), thermoplastic polyurethane (TPU), ethylene vinyl acetate (EVA), and ABS. According to Sculptify, the 1-kg bags of PLA pellets optimized for use with David will ship for $18, whereas a 1-kg spool of plastic normally costs roughly $48.

A 10 kg bag of optimized ABS pellets will sell for $18 as well, while EVA and TPU will be priced at $22 per 1-kg bag. Sculptify is currently optimizing HIPS, HDPE, polyamide (PA), polycarbonate (PC) and wood composite.

Sculptify notes that users do not need to buy pellets from its website since they are widely available and can be found on many 3D printing and plastic supply websites in varying types and sizes. However, there are certain grades, sizes, and shapes that are optimal for use with David, and there are some that simply won't work with the system. On this account, pellets will also be available through the Sculptify store to give those who do not want to experiment proven material options for everyday printing.

"David provides customers with the freedom to choose from an extensive selection of materials - which range from hard and durable to soft and flexible. By eliminating the dependence on filament, Sculptify can offer exotic materials and composites never before used in 3D printing," said Luke Daniel, Director of Business Development.

David possesses a build volume of 20 x 22 x 18.5 cm, with nozzle sizes of 0.3 mm, 0.4 mm and 0.5 mm included. Layer resolution in the case of PLA is 20 microns. Positioning precision is reportedly 8 microns or better in the XY axis and 3 microns or better in the Z axis direction.

"David is an incredibly versatile device, that can be used by both consumers and prosumers alike," said Slade Simpson, Sculptify Co-Founder and CEO. "Sculptify believes that for 3D printing to reach its fullest potential, printers need to be able to serve hundreds of different purposes. We think that FLEX technology is the next logical step in making this possible."

"We think that FLEX printing is going to open the door to hundreds of new applications in both the consumer and commercial sectors because of the unique, and growing material library - we are venturing into a new realm of 3D printing," said Todd Linthicum, President and Co-Founder. David features both groundbreaking technology and commercial-grade components, all specifically designed to provide versatility, speed, and accuracy. Further, a removable print platform and easy loading system reportedly makes David as easy to use as it is powerful.