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HARDCORE 3D PRINTER POWDER

“HARDCORE” 3D PRINTER POWDER FORMULA:

This formula makes 119 pounds of powder that can be used in 3D Systems ProJet x60 series full color 3D printers. Powder settings must be set to use ZP130[1] powder settings or if not available as an option on your printer, then a new custom powder must be derived according to the  instructions here https://www.noble3dprinters.com/tech-support/3d-printer-powder-settings/ Also we will be including where to source the materials and how they must be formulated, (mixed) Failure to follow these instructions implicitly will cause your batch to fail.

INGREDIENTS: (all are measured in weight not volume)

  1. 100 LB bag of “Hydrocal White”
  2. 15 LBS Polyvinyl Acetate (sieved to 88 micron)
  3. 2 LBS Calcium Phosphate (Bone Ash)
  4. 1 LB Terra Alba* (Gypsum)
  5. 0.5 LB Potassium Sulphate* (potash of sulfate)
  6. 0.5 LB Mineral Oil (applied with spray bottle before mixing and sieving ingredients)

*All materials must be sieved through an 88 micron stainless steel screen. Instructions on how to build your own powered sieve from a cheap harbor freight cement mixer will follow soon. In the mean time you can purchase a hand powered sieve, (be sure to get the #200 mesh screen) at  https://www.sheffield-pottery.com/TALISMAN-COMPLETE-GLAZE-SIEVE-p/ts363.htm?_vsrefdom=adwords&gclid=CjwKCAjw7O_pBRA3EiwA_lmtfnrHJBmWOtQhBnGczHqafrjJuBiUaV83BeiNnVy29IlFdoxhgKQN8RoC26kQAvD_BwE Step by step videos are being made.

MIXING INSTRUCTIONS:

1.) Sieve enough Polyvinyl Acetate to make 15 lbs of sieved powder. (Save the powder that does not go through the screen as we will show you how to grind this down using a 55 gallon stainless steel drum modified to be a giant rock tumbler that is powered by tuning an electric wheelchair upside down and setting the drum between the chairs wheels. The drum must be able to hold a vacuum because you will be putting dry ice inside with the grinding media. Its the only way known in the world to grind this powder down as it is friable which means when you hit it with a hammer it doesnt fracture, it simply deforms, hence the need to freeze it with dry ice to make it brittle. We had the world's leading air jet mill company attempt to grind it down but they were unsuccessful as the milling process produces condensation which turns this powder into white glue. Yes this powder is what is used to make white glue, just add water. Its also used to make bubble gum! Wacker Chemie is the leading manufacturer. You want to order their "Vinnapas B 60 FG" from http://www.brenntagsolutionsgroup.com)

2.) Sieve your Potasium Sulfate through your #200 mesh screen until you have a pound of sieved fine powder. Save what does not go through the screen as you will be using it in your clear binder. (Note: You can find a lot of chemicals on ebay, but this one is hard to find in its pure form. E.g., in a fine enough grade to use in your clear binder. They do sell this in pure form at dentist supply stores. Its used as a fixative. Name brand that I have is from "DUX Dental", If I remember correctly this company is no longer in business, but I'm sure someone sells it in pure form. The stuff on ebay is usually a lower grade used as a fertilizer, (if you purchase this fertilizer grade, be sure to get the water soluable grade, I believe "Kelp for Less" is a good outfit to buy from) which is fine for the powder, not not the binder. Keep this in mind)

3.) Measure/weigh out 2 lbs of Calcium Phosphate a.k.a. Bone Ash in some circles, (this gives our powder its whiteness. This is the main ingredient used to make bone china)

4.) Into a squirt bottle pour 0.5 pound, (227 grams) of mineral oil. Make sure you tare/zero out your scale with the bottle on it before you start pouring.

Now there are two ways to go when mixing and sieving all the ingredients together: the long way and the short way. We prefer the short way as it saves hours of sieving.  

5.) After all the above ingredients have been sieved, (dont skip this part or your just wasting your time because your powder wont work if you do. If you dont believe me, please skip the sieving and watch your prints get dragged across the bed each time a new layer is spread)