RePLAy 3D
Converting a 3D printer to print directly from
pellets requires tradeoffs: you’ll gain the ability
to reuse plastic material in exchange for some
performance limitations.Done carefully, these
modifications will open the door to closed-
loop recycling, economical pellet feedstock
($2–$5/kg), custom material blends, colors, and
properties — but they could reduce the usable
print volume and require slower print speeds due
to the toolhead’s weight. Ten things to consider:
1. Can the carriage handle the weight and
dimensions of the pellet extruder and hot end?
Consult your vendor(s). We mounted the Lily pel-
let extruder on a SmartAlu printer designed by
Smartfriendz (above).
2. Obtain a copy of the firmware on your printer —
you may need to modify it.A lot of modifications
can be stored in your slicer profile, but various
offsets may have to be changed in firmware.
3. Your Z-axis endstop may have to move if the
pellet extruder has a long hot end (the Lily does).
4. If you use a BLTouch or induction sensor for
bed leveling, you might have to redesign a new
X-carriage to accommodate these elements.
5. If possible, make the conversion on a
secondary printer in case you need your main
printer to prototype parts.
6. Decide how you will feed the pellet extruder.If
you’re using a gravity feeder, the hopper has to
be above the printer.The Lily pushes filament
through a PTFE tube using air, so the pellets or
shreds can be fed from any level.
7. While V-wheels are great, expect wear
to increase with the heavier head. Consider
upgrading at least the X-axis to use a linear rail.
8. If your kit comes with a MOSFET, use it.
Running the pellet extruder may consume
more power than your printer’s original
design.Make sure your power supply can
support the additional load.
9. Once it’s all installed, you’ll want to experiment
with different materials to determine optimal
print speeds, jerk settings, and retraction rates.
10.
Expect to tune your PID values to suit your
extruder.Recycl3D provided me with a baseline
set of numbers and I tuned accordingly.
Whatever extruder you choose, seek support
from your vendor, as this is a non-trivial
endeavor.They’ll have complete details —
Recycl3D was in close contact throughout my
Lily installation over several weeks.Of course,
if you’re using a DIY pellet extruder, the same
checklist applies, but otherwise you’re on your
own. You can find many #pelletextruder sources
on YouTube, Thingiverse, and other sites.
CONVET A PRINTER TO
PELLET EXTRUSION
10 top tips for making the switch Written by Samer Najia
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