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[E1][B][R] Coaxial8or R1 print costs $47, and failed simulation attempt

A project log for Coaxial8or [gd0144]

Full-colour FFF? Multi-materials with unparalleled interlayer bond strength? Abrasives without abrasion?

kelvinakelvinA 04/07/2024 at 13:310 Comments

PCBWay pricing for Coaxial8or R1

Amazing cost reductions!

Perhaps it's because this design is similar to R0 which PCBway already has experience on, but now the autoquote and the actual price were essentially identical. Unexpectedly, the "Standard Global Shipping" is now almost half the cost. Perhaps it has something to do with the bounding box of R1 being smaller than 50 x 30 x 50mm3?

Another possible reason for the lower price could be that the 1.5mm channels are easier to clean inside than the 1.25mm ones? 

The current Mastercard conversion rate means that it will cost me £45.25.

Simulation attempts

I was going to install the Windows Subsystem for Linux to try OpenFOAM, but then I found out and tried to use the injection moulding simulation feature in Fusion 360. Unfortunately, it complains if I set the mould temperature to something like 236C for PETG, and when I set it to within the recommended values, I got an incomplete fill animation:

I can use my imagination for this much of a simulation.

[Apr 07] There was a material called "Bionolle" that had a close melt and mould temperature of 115C and 80C respectively, and I moved the inputs so that I could at least see the filling of the coaxialiser and path length matching. 

Allegedly, the material will expand into the empty space from both directions instead of only clockwise.
It seems that the paths for all 8 inputs are matched to within about 1.5mm. Hopefully, this means that the pressure difference between the splitting paths is low.

[End of Apr 06 edit]

I signed up for SimScale but it became apparent very quickly that I'd only be able to simulate liquids like water and oil.

Ideally, it seems that I'd need something like Ansys Polyflow, which seems to be able to simulate coextrusion:

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