Stainless steel SLM version

Has anyone tried this in stainless yet? The flexure is probably a lot stiffer, so some design mods would be needed, but 3d printed stainless is somewhat reasonable now - about $500 to have the block stage printed and shipped. The “leg test” is $12 with slow shipping. A flexure test piece would probably be even less.

If someone with detailed knowledge can point me at the right general area to look, I can model and print a flexure test piece or three and probably give you some decent numeric data on things (bend force vs. flexure). I have access to a precision pull tester, calipers, and have some vague idea what I’m doing (I am a staff EE but use SolidWorks for art all the time.)

Is there already a general flexure test piece somewhere in the project history?

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The leg_test.stl is a good start for understanding whether the printing process will work for the complete structure, and it will show how stiff the structure is. I don’t think we have particular numbers for stiffness but you could compare to a PLA version. We do have a specification for the range of deflection, which is 6 degrees either side of central.

To make flexure tests, with two blocks joined by a flexure of our dimensions, the flexure dimensions are in the flex_dims() (in millimetres) with:

width of flexures: flex_w = 4
length of flexures: flex_l = 1.5
thickness of flexures: flex_t = 0.75

In stainless steel I expect the thickness will need to be less, and then it will be interesting to see whether they can flex many times without breaking.

Obviously, for the complete structure there would need to be a number of changes, particularly in the fastenings changing the nut traps and self-taping screws to threaded holes (apart from the nut trap in the actuators where you still need a brass thread). That should be relatively straight-forward for the Microscope v7 as these items are centrally defined in modules, the block stage had more things hard coded at each place.

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actually, unless you bend the legs of the stage with heat (like on bimetal-strips), i would assume, that any metal version of the center-stage would fatigue MUCH quicker, than any plastic-printed one.

Lets leave SLM-printing aside for a moment, and just assume machined or cast steel parts. during the process of manufacturing the metal cools down unevenly around something called cristalization points.

The only thing that matters is, that the metal has some inherent defects in it’s structure on various levels of magnification. the level we are interested here is the crystalline grid that forms all metals on a microscopic layer. defects spread out somewhat uniformly thoughout the whole metal part gives it some interesting properties. When physically deforming the metal (in a cold state) beyond it’s flexible limit, those defects clash together and inter-twine and form a much stronger bond at the affected area. however, because that bent section is now much stiffer, it is basically impossible to deform it back to original. the most quoted example for this are paperclips. straigthen them out, and try to bend them back in shape, there will always be additional kinks in the metal. Now imagine the flexure-stage to be bent back and forth alot. It would fatigue very quickly. To “reflow” the metal back to it’s more defective and more malleable state, you do something called tempering (in case of steel: heating it to a few hundred degrees and let it cool down reeeealy slowly).

So obviously Plastic deformation as described above isn’t useful here (unless induced by heat), and we want to stay in the limits of flexible deformation. I don’t have the exact numbers in mind, but I’d assume for most metals the flexible deformation range is likely much less than e.G. PLA. Most likely you’d have to get the bendy-parts VERY thin for this to work, and i suppose the rather bumpy surface of SLM-printed parts doesn’t do us a favor either here. if you don’t nail the perfect thickness 100%, the motors will not be able to bend the legs anyways. the sweetspot is most likely a very narrow range of thicknesses. all bending sections should ideally be machined instead. Another problem (on long, very thin metal strips that translate motion with a rather big ratio) would be, that you will have an excessive amount of drift induced by temperature changes. You really cannot produce “living hinges” like on a plastic lunchbox in metal, at least not within reasonable assumptions.

With much softer materials this will most likely work better, but gold, silver, lead or even soldering-tin are all wildly unpractical, expensive or harmful. copper might also work though.

However, using bimetal strips are still wildly impractical, but it would be a very fun idea nontheless, and it might even work reliably good, but you have to alter the construction quite alot, otherwise your o-rings would just melt…

(P.S.: I learned alot of metallurgy in my training way back in the day, however, i am not a material scientist, and have no specific numbers to back up my claims, but from 15+ years of experience working with metals daily, I’d assert that the above claims are somewhat grounded in reality. in the end openflexure is designed to be printed in plastic. if you want to build this in metal instead, much different design-considerations apply, even if you SLM-print it instead of just machining everything…

P.P.S.: as I speak german as my first language, and not english, some specific technical terms may by slightly off-spec :slight_smile: )

Well…

  1. Leaf springs are steel.

  2. Apparently there is at least one company making SLM springs and selling them.

  3. Steel has an endurance limit, unlike most other metals.

So I think it’s worth $25 of my money to try the leg test piece (slightly modified), and go from there, but I would like to understand it better so I can do a test piece with several geometries. Time to do some reading…

What’s the force applied to bend that flexure 6 degrees? I assume that’s mostly a gear ratio… I’ll order half a dozen blocks+flexure in stainless and test them out. With some really janky calculations I have: flex_t=1mm, flex_w=5mm, flex_l=41.5mm (!!!) as a starting point.

I wonder if the SLM springs are tempered after production? If it is brittle it may be worth seeing if you can temper it. Steel is crazy (I have less experience of stainless) you can go from brittle like glass to very malleable with the same metal with different heat treatments.

I think the big issue is work hardening, I am not sure if the stress/movement in the bottom flexure under foot would be enough to work harden and crack. Still, I have always wanted to see a metal OpenFlexure, so I love that you are trying this!

As I can recognise this project is really all about keeping costs low and focusing on the software. The hardware? It’s… fine. It works as it is.

If someone actually wanted to build the microscope using steel, brass, and aluminum, the whole design would need a serious rethink. 3D-printed steel is a super niche thing—mostly used for very specific projects where regular 5-axis CNC milling isn’t an option, and where the production volume is way too small to justify casting in a proper foundry.

Metal parts are usually made subtractively, which is fast and cheap. You don’t even need your own tools—there are online services that’ll ship custom parts straight to your door. For example, you could make the body out of S235JR steel and weigh it down with concrete.

The Problem? Design rules for additive and subtractive manufacturing are totally different. You can’t just make any shape by bending sheet metal, turning, or milling. Hollow bodies, for instance, can be a real challenge. So the design would definitely need to be adapted.

The good news? Brass and steel actually make a great combo in terms of mechanical properties, optics, and even aesthetics.

Bottom line: it’d be a pretty major overhaul—at least on the hardware side.

For the existing design, if I go to a particular spot, take an image, and then wait 4 hours and take another, are the images aligned?

Ordering one or two of these shortly - 3, 4, 5mm beam widths, 0.8mm thick, 41.5mm long. Anything else I should try?

The images will be aligned within a few microns.

The focus will also drift a little. I have done long term (days) timelapse of samples, using autofocus each time to make sure that is nailed. The xy drift is very small, but if you need alignment at the level of the microscope resolution you would need to do some image registration afterwards.

What is the thinnest practical beam? Shorter and thinner will be more practical in the end.