3D printed coil housing

[ivconic]

[ivconic]

I made wide and deep channel for pvc litz cable windings. It turns out that such coil is very fast and with very good characteristics.
Made such coils for FelezJoo Pi (380uH) and for Pulse Star II (680uH).
We know how FelezJoo is "picky" on coils, pvc litz cable one performs excellent with it.
Therefore the wide and deep channel in enclosure.
STL files:

[ivconic]

Overall there are 18 files, each one printed separate.
D2 and D2 with tiny channel for the wire to rech the center. So 19 files actually.
On some of those there is "under extrusion" problem visible.
That's because my printer goes wild from time to time, springs for bed leveling are not good anymore, need replacement.
Yet, I use cheap hair spray to fill the gaps temporary, later the epoxy will fix the construction for good.
The "design" is not too fancy, can be done better, more "wildly"...

[Mdtoday]

Nice work, what density do you print at?
Do you coat the housing with epoxy?

cheers

[ivconic]

Cura 5.2.1 profile, you can review the settings from it.
Later when coil is made and put into housing; epoxy comes right after.

[MartinB]

Nice colour
What filament did you use?

[ivconic]

I am using this one for the first time and I must say I am not happy with it.
Under extrusion started exactly with this one, once I put it on printer.
Yes my bed is not leveled perfectly, springs are tired and need replacement.
But I never had such problems until now.
Just yesterday, by random experiment; I discovered that it will print fine only if I adjust nozzle temperature to 230 degrees !!!
With other brands usually I print with temperatures between 190 and 200 at most.
So finally yesterday (spool on half already) I got fine printed piece of plastic, but with temperature high as 230 degrees!
The rest of adjustments are just common.
Coil from pictures above was printed at 200-220, 18 parts so I changed adjustments during the printing to find best one.
That's why some parts are fine and some are under extruded with gaps.
...
Color... I like to experiment with fancy colors. Sometimes you get unexpected results!

[ivconic]

The best filaments I can obtain in local shops are these:
https://gigashop.kpizlog.rs/search.p...%5D=Tra%C5%BEi

Maybe I'm just imagining this, maybe it's not true... but it seems to me that not all colors melt the same. From the same brand.
I've had the printer since August 2018. So far, I've found that black, bright red, purple, and dark lemon yellow produce the finest print.
It seems that the pigment they add to the plastic; affects the thermal properties of plastic.
And maybe I just made it up...

[GeoMax]

I made wide and deep channel for pvc litz cable windings. It turns out that such coil is very fast and with very good characteristics.
Made such coils for FelezJoo Pi (380uH) and for Pulse Star II (680uH).
We know how FelezJoo is "picky" on coils, pvc litz cable one performs excellent with it.
Therefore the wide and deep channel in enclosure.
STL files:

Hi Ivconic,

what litz wire have you used? I mean how many wire strands and wire diameter? Have you shielded the coil?

[ivconic]

Hi Ivconic,

what litz wire have you used? I mean how many wire strands and wire diameter? Have you shielded the coil?

Not made yet.
Last time I made similar coil was several years ago, for FelezJoo PI.
As I recall, 0.75mm pcv litz cable was used.
How many litz? Never counted, don't know.
Using that cable with soft pvc coating; I made number of turns enough to match 380uH inductance, and that was all.

[MartinB]

I have also found that some colours do not print as good as others. PLA is not the best material as it is not UV stable and deteriorates in sun light, also it is not impact resistant. I have had a look at your suppliers web site and suggest that you use ABS. It is stronger, impact resistant and more stable. Use nozzle temp of 245 and bed 110. Personally, I prefer ASA-X which is equal to ABS but I find it prints better at the same temperatures. Yes, you can also buy it in some crazy colours.

[ivconic]

I have also found that some colours do not print as good as others. PLA is not the best material as it is not UV stable and deteriorates in sun light, also it is not impact resistant. I have had a look at your suppliers web site and suggest that you use ABS. It is stronger, impact resistant and more stable. Use nozzle temp of 245 and bed 110. Personally, I prefer ASA-X which is equal to ABS but I find it prints better at the same temperatures. Yes, you can also buy it in some crazy colours.

Thanks!
I never even considered ABS until now, will see.
As for UV; I saw there is "curing" process after the printing. They even sell separate "device" for UV "curing".
So, is it help to stability anything or not?

[ivconic]

Some of my current, ongoing, works and prints.

[ivconic]

The white one is ABS stock enclosure. Pity it is 2.5cm shorter than what I needed. So I had to draw it and resize it, to make the volume enough for the device and all the parts.
Printed one; black part is under extruded as it can be easily seen.
But I think I have found a way to make it better, as I mentioned; i fill the "gaps" with cheap hair spray and later on paint with black paint. A bit of fine sanding paper in between.
Hair spray stays in, in form of "epoxy resin" kind, once dried well. The gaps are filled and the construction is tight and strong.
The purple part is printed well. I planned to paint it also in black, but I changed my mind later, because this combination of colors is not bad at all!

[GeoMax]

Wow...
excelent job done !!!