Imagine a Simpson type format robot with the ability to shape metal into near net shape. I propose such a robot could use 2 simple toolheads to accomplish this:
One tool head equipped with a wire feed (much like a filament feed) and a cutting solenoid. This tool head would push out wire downward into a bed of styrofoam (or other material that would hold the wire) at varying lengths, depending on the topography of the part being printed. Each XY coordinate on the print bed would be handled this way until a "bed of needles" is formed with the rough topography of the part being made.
The second tool would be equipped with a small propane torch and a tiny ballpoint hammer, actuated by a solenoid. After the first tool is done placing each wire, the group of wires would be clamped together. Then the second tool would be used to heat and then hammer the wires downward into the final shape of the part. Each small hammer blow would "upset" the wire so that it would expand slightly, filling the gaps between the wires, effectively forge welding the wires together. Once the top of the part (the part with details) is complete, the part could be turned over to each side so that it too could be (welded).
Advantages (that I can think of):
Low motor strength needed (compared to other CNC machines)
Open control scheme, like other repraps
Uses a robot that could then be used for normal 3d printing
Shapes metal!
Disadvantages:
Limited part shape (can be overcome with multi-piece parts)
Probably pretty loud (compared to a regular 3d printer
Manual intervention required mid-print (going from toolhead 1 to toolhead 2)
What could you make with such a machine? I think the largest potential would be moulds for other parts. If you were willing to assemble a few parts together then you could probably make quite a few things.
One tool head equipped with a wire feed (much like a filament feed) and a cutting solenoid. This tool head would push out wire downward into a bed of styrofoam (or other material that would hold the wire) at varying lengths, depending on the topography of the part being printed. Each XY coordinate on the print bed would be handled this way until a "bed of needles" is formed with the rough topography of the part being made.
The second tool would be equipped with a small propane torch and a tiny ballpoint hammer, actuated by a solenoid. After the first tool is done placing each wire, the group of wires would be clamped together. Then the second tool would be used to heat and then hammer the wires downward into the final shape of the part. Each small hammer blow would "upset" the wire so that it would expand slightly, filling the gaps between the wires, effectively forge welding the wires together. Once the top of the part (the part with details) is complete, the part could be turned over to each side so that it too could be (welded).
Advantages (that I can think of):
Low motor strength needed (compared to other CNC machines)
Open control scheme, like other repraps
Uses a robot that could then be used for normal 3d printing
Shapes metal!
Disadvantages:
Limited part shape (can be overcome with multi-piece parts)
Probably pretty loud (compared to a regular 3d printer
Manual intervention required mid-print (going from toolhead 1 to toolhead 2)
What could you make with such a machine? I think the largest potential would be moulds for other parts. If you were willing to assemble a few parts together then you could probably make quite a few things.