Recently, researchers at Purdue University in the United States have developed a new system that can be combined with a 3D printed functional product that encapsulates electronic circuits and engine components. The system, called "RevoMaker", allows users to print on a rotating axis instead of a standard print bed, and can be used to grow custom devices, such as computer mice that are shaped according to the shape of the user's hand.

As is well known, most 3D printers typically print objects layer by layer from bottom to top, creating objects that are more complex than traditional manufacturing methods. However, typical 3D printing techniques also have their own problems. For example, to print a drape or an object with outstanding features, such as extended arms, a detachable support is required.

The RevoMaker system not only reduces the need for support structures, but also uses a new technology for multi-directional 3D printing. Most importantly, the system can print out certain functional products directly without the need for assembly. We can see that many electronic devices use a variety of structural components around their electronic components to bring all the components together, and RevoMaker can print a complete perimeter structure around the electronic component 3D in one printing process. "With our approach, it will soon be possible to manufacture functional products using 3D printers," said Karthik Ramani, a professor of mechanical engineering at Purdue University. The process consists of a square box with electronic and power components mounted, which is attached to a rotating shaft and then printed on it by a 3D printer that can be rotated at any time for the 3D printer to start printing. The other side of it, or continue on the existing print layer.

“With a traditional 3D printer, we can print on a flat print bed and the print platform is fixed,” says mechanical engineering professor Raymond Cipra. “And our strategy is to turn the print bed into a laser-cut rectangular box. The cuboid can be rotated around an axis, and then the 3D printer can print on each side of it. Before printing, the cuboid can be loaded into electronics, motors, batteries, etc."

In fact, RevoMaker itself is not a 3D printer, but a mechanical system that can be used on consumer-grade 3D printers. All users need to do to replace their existing 3D printing beds with multi-axis devices. . “Our focus is on improving current 3D printers with minimal cost and complexity, eliminating the need for more complex and expensive multi-axis equipment.” One of the participants in the project, student Wei Gao. “Through a rotating cuboid and using the 3D printer's own X/Y/Z stepping control, we have added more features and capabilities to the technology. This technology can also achieve side-by-side functionality, such as buttons. ""

Each cuboid in the system is tailored to specific 3D printing jobs, reducing material waste and making 3D printing more efficient. Sometimes it can lead to 3D printing time and material reduction of up to 37%. “We calculated the optimal size of the cuboid needed inside the geometry model according to our own algorithm,” explains Yunbo Zhang, a postdoctoral researcher. “In order to save the printed material of the entire object, the algorithm optimizes the volume of the cuboid as much as possible, which will reduce the volume that needs to be printed as much as possible.”

“This system can achieve more efficient and personalized manufacturing than traditional 3D printing methods,” Ramani said. “In the future, people can use it to customize some modular, low-volume products.”

The RevoMaker team does not currently have a plan to commercialize the system. Instead, they want to see this project attract more fans and developers. “RevoMaker subtly integrates several engineering innovations to further enhance the capabilities of additive manufacturing technology, making it more efficient and easier to use for users of all ages,” said Ed Murris, director of America Makes. The potential applications of improved technology range from interesting production of custom toys to the creation of dynamic teaching tools, as well as the creation of customized functional devices for people with disabilities to improve their quality of life."

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