During v4, myself, @timslab, and @peter-bas were working on extruder development, with a focus on industrial beam output. You can see more here:
Our machine here in the Maldives is not what we were operating and testing with during v4. That being said, we are semi limited in several categories:
Width and Lengh
I like to think the setup we are using here is more aligned with the extruder build most people are running, which is the current model PP has released.
So far, we have found that it is hard to find thick gauge steel tubing / and or does not exist here. Tubing is also almost always galvanized here, which means welding it without grinding is unadvised, due to zinc poisoning.
With those things in mind, we have already begun production of a 40×40 by just shy of 2 meter length. We purchased a 3 meter length of 22 gauge tubing from a local metal distributor and got to work.
Due to sketchy stick welding setups on thin gauge tubing and using scrap steel for bolt connections to the machine, we are getting the beam out of the mold from the non machine end, so we dont have to worry about any weld splatter / extra material getting in the way of removing the beam.
(Past beam molds were removed from the machine end, but with the upgraded v4 machine, we were able to keep the mold on the machine, and after a cooling period, restart extrusion which would push the old beam out of the mold.)
By extruding just to the 2 meter length, after a quick 10 min ocean cooling, the beam slides right out real easy. We are not producing extremely smooth beams, like ones seen in our v4 production, but they are also not extremely haggard, and very usable.
We have found that extruding a beam over 2 meters results in difficulties removing the beam from the mold. We believe this has to do with inherent pressure build up over length. We prefer not to use mold release if we can.
That’s all for now!
I leave you with a photo of our current little setup.
photos of the beam mold(s) will come within a week
Take it easy!