Joel Galos, Ph.D.

Joel Galos, Ph.D.Joel Galos, Ph.D.Joel Galos, Ph.D.
  • ABOUT
  • RESEARCH
  • PUBLICATIONS
  • TEACHING
  • GALLERY
  • 3D PRINTING
  • AWARDS
  • CONTACT
  • BLOG
  • More
    • ABOUT
    • RESEARCH
    • PUBLICATIONS
    • TEACHING
    • GALLERY
    • 3D PRINTING
    • AWARDS
    • CONTACT
    • BLOG

Joel Galos, Ph.D.

Joel Galos, Ph.D.Joel Galos, Ph.D.Joel Galos, Ph.D.
  • ABOUT
  • RESEARCH
  • PUBLICATIONS
  • TEACHING
  • GALLERY
  • 3D PRINTING
  • AWARDS
  • CONTACT
  • BLOG

MATE Polymer & Composite 3D Printing Lab

The Cal Poly SLO Materials Engineering (MATE) Polymer & Composite 3D Printing Lab is a dedicated space that gives students access to cutting-edge polymer and polymer composite 3D printing technologies.  The space is used for lab class, industry-sponsored senior project research and independent study. 


The vision is to become a leading ‘Learn by Doing’ lab known throughout California.

PART Gallery

Bicycle crank arms (printed with carbon fiber reinforced nylon composite)

    KEY TECHNOLOGY

    3DGENCE F350

    MARKFORGED MARK TWO

    MARKFORGED MARK TWO

    Designed for engineering grade and composite materials, fully compatible with high-temperature polymers (PEEK, PEKK). The F350 provides high-speed, repeatability, reproducibility, and reliability.

    Learn More

    MARKFORGED MARK TWO

    MARKFORGED MARK TWO

    MARKFORGED MARK TWO

    The Markforged Mark Two Desktop 3D Printer is capable of creating aluminium-strength parts with patented CFR™ (Continuous Fiber Reinforcement) technology.


     

    Learn More

    PRUSA MK4

    MARKFORGED MARK TWO

    PRUSA MINI+

    The MK4 provides high-speed 3D printing with ease. The successor to the award-winning 3D printing workhorse Original Prusa MK3.



    Learn More

    PRUSA MINI+

    FELFIL FILAMENT EXTRUSION SYSTEM & SHREDDER

    PRUSA MINI+

    Featuring a 7"×7"×7" build volume, the MINI+ is a fully-equipped 3D printer. Featuring sensorless homing, automatic Mesh Bed Calibration, replaceable nozzles, network connectivity, USB printing and a full-color LCD screen.


    Learn More

    FELFIL FILAMENT EXTRUSION SYSTEM & SHREDDER

    FELFIL FILAMENT EXTRUSION SYSTEM & SHREDDER

    FELFIL FILAMENT EXTRUSION SYSTEM & SHREDDER

     This extruding system allows anyone to make custom 3D printing filaments, starting from industrial pellet or chopped scrap 3D prints, and plastic waste.




    Learn More

    3DGENCE MATERIAL MANAGEMENT SYSTEM

    FELFIL FILAMENT EXTRUSION SYSTEM & SHREDDER

    FELFIL FILAMENT EXTRUSION SYSTEM & SHREDDER

    The Material Management System automates material storage, preparation, and post-print annealing – making  successful printing of Ultra-Polymers like PEEK, ULTEM™, and Composites accurate and simplified.   


    Learn More

    3D Printing Process

    The MATE Polymer & Composite 3D Printing Lab primarily employs Fused Deposition Modeling (FDM) processes. 


    FDM is an additive manufacturing technique suitable for use in an office environment. A fine stream of molten material (usually thermoplastic) is deposited by a heated extrusion head. Semi-liquid thermoplastic material is extruded and then deposited one layer at a time starting at the base. This builds the model vertically on a fixtureless base. Successive layers adhere together through thermal fusion. The FDM process requires no post-production UV curing, enabling multiple versions of a part to be created within a short time frame. This is the most widely used additive manufacturing method for home and office use due to the low machine and operating costs. As with other additive manufacturing processes, a CAD solid model of the part is required.


    The process is also known as Fused Filament Fabrication (FFF) or plastic jet printing.


    Reference:

    Granta EduPack 2022 R2, Cambridge, UK


    Materials

    • Thermoplastics (e.g. PLA, PETG, ABS, ASA)
    • High temperature thermoplastics (PEEK, PEKK)
    • Thermoplastics with short fiber reinforcement (carbon fiber -CF, glass fiber -GF)
    • Continuous fiber composites (carbon fiber, glass fiber, aramid fiber)


    A comparison of common thermoplastic filaments can be found here.

    3DGENCE F350

    Printing technology

      Fused filament fabrication (FFF)

    Max. build/print size

      340 x 340 x 350 mm 

    Printer footprint

      1825 x 960 x 940 mm

    Print layer height

      ~50+ μm

    Filament diameter

      1.75 mm

    No. print heads/nozzles

    2 (printhead purging system)

    Relative print speed

    High

    Max. nozzle temperature

    ~500°C

    Max. build plate temperature

    160 °C

    Max. chamber temperature

    140 °C (active heating)

    Typical materials

     PLA, ABS, ASA, PA6, PA, PC,  PEEK, PEKK, -CF,-GF 

    Overview

     3DGence FFF 3D printing platform

    Overview

    Heated material chamber

    MARKFORGED MARK TWO

    Printing technology

    Fused filament fabrication (FFF)

    Max. build/print size

    320 x 132 x 154 mm 

    Printer footprint

    584 x 330 x 355 mm

    Print layer height

     ~100 μm

    Filament diameter

     1.75 mm (plastic), 0.375 mm (fiber)

    No. print heads/nozzles

      2 (1 plastic, 1 fiber)

    Relative print speed

    Low

    Max. nozzle temperature

    ~300°C

    Max. build plate temperature

    n/a

    Max. chamber temperature

    n/a

    Typical materials

    Plastic nozzle:  PA6, PA6+short carbon fiber

    (Continuous) Fiber nozzle:  carbon, glass, HS glass, aramid (Kevlar)

    Overview

    3D Printing strong parts in continuous carbon fiber

    Tutorial

    How to load & unload material

    Tutorial

    Introduction, bed leveling, printing, settings 

    PRUSA MK4

    Printing technology

      Fused filament fabrication (FFF)

    Max. build/print size

    250 x 210 x 220 mm 

    Printer footprint

    530 × 545 × 640 mm (in enclosure)

    Print layer height

     ~50 - 300 μm

    Filament diameter

     1.75 mm

    No. print heads/nozzles

    1

    Relative print speed

    High

    Max. nozzle temperature

    ~300°C

    Max. build plate temperature

    ~120°C

    Max. chamber temperature

    n/a

    Typical materials

      PLA, PETG, ABS, ASA, Flex, HIPS, PA, PVA, PC, PP, CPE, PVB, NGEN, short fiber composites

    Overview

    Original Prusa MK4 - always perfect first layer, 32bit board, Nextruder, Input shaper

    Tutorial

    PrusaSlicer beginner tutorial: learn the basics

    Tutorial

    New User Guide - Original Prusa MK4

    PRUSA MINI+

    Printing technology

      Fused filament fabrication (FFF)

    Max. build/print size

     180 x 180 x 180 mm 

    Printer footprint

    380 × 330 × 380 mm

    Print layer height

    ~50 - 250 μm

    Filament diameter

    1.75 mm

    No. print heads/nozzles

    1

    Relative print speed

    Intermediate

    Max. nozzle temperature

    ~280°C

    Max. build plate temperature

    ~100°C

    Max. chamber temperature

    n/a

    Typical materials

    PLA, PETG, ASA, ABS, PC, PP, Nylon


    Overview

    Original Prusa MINI is here: Smart and compact 3D printer

    Tutorial

    Prusa Mini+ video user guide (Cal Poly)

    Tutorial

    3D printing for beginners in 2021 feat. Prusa MINI+

    Tutorial

    First layer calibration and filament loading

    FELFIL FILAMENT EXTRUSION SYSTEM & SHREDDER

    Overview

    Felfil System is the most compact filament extrusion system on the market. It allows to produce the filament for your 3D printing starting from virgin pellet or shredded recycled materials. The system is a full setup that includes everything that is needed to develop and produce filament for any FDM 3D printer, it includes:

    • Felfil Evo, a single screw filament extruder with a specifically designed bronze nozzle.
    • Felfil Spooler, an automatic filament winder.
    • Felfil Shredder, a small but strong plastic shredder able to crush failed 3D prints or plastic waste.

    Overview

    Felfil: Make your own filament

    Tutorial

    Felfil Extruder and Spooler+ video user guide (Cal Poly)

    Tutorial

    Felfil Shredder video user guide (Cal Poly)

    Tutorial

    Felfil Spooler: first steps with our filament winder

    3DGENCE MATERIAL MANAGEMENT SYSTEM (MMS)

    Overview

    The 3DGence MMS automates material storage, preparation, and post-print annealing – making  successful printing of Ultra-Polymers like PEEK, ULTEM™, and Composites accurate and simplified.  

    Overview

    Material Management System-way of increasing the strength of a 3D printing parts.


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