Hybridized 3D-Printed Part Combines Plastic and Metal

A prototype of a rifle magazine made using hybridized 3D printing consists of has the thermoplastic printed part (above) combined with a high-wear component made of aluminum.

When a client quickly needed a working prototype of a rifle magazine, the designers and technicians at Baklund R&D, Hutchinson, Minn., knew they would have to use hybridized 3D printing. It’s a manufacturing technique that combines parts made of metal, wood, or molded plastic with printed thermoplastic parts or housings. In this case, a high-wear component was machined out of aluminum and integrated into the printed thermoplastic magazine.

Hybridized 3D printing was developed to overcome the structural and aesthetic shortcomings of printed thermoplastics. Printed plastics are weaker than molded plastic and in most cases will not endure the abuse often required during testing. One option is strengthen components, but then they may need to be up to twice as thick as molded plastic to withstand similar forces. Many times this is not an option due to the need to maintain accuracy in parts size and operation.

Hybridization, on the other hand, creates accurate prototypes of final parts out of plastic, wood, steel, aluminum or virtually any other type of material that is required. The hybridized part can meet specifications for high-wear components, the need to have different types of materials and densities in specific areas of the prototype, or simply for aesthetics.

A great example of this can be seen in the assembly recently developed by Baklund R&D, which integrated an aluminum high wear section on a rifle magazine. Combined with the ability to quickly 3D print the rest of the model, hybridization not only let Baklund build a prototype that could withstand the required testing, but also let the company deliver the project to the customer more quickly than other suppliers, who would have relied only on additive 3D –printing processes.

As this hybridization technique becomes an accepted technique, engineers should be able to create more functional prototypes, as well as more production-ready products. The hybridization technique will translate to a reduction in time to market and reduced development costs; it will also allow for designs to be optimized beyond their current limitations, as designs that were not possible before can now be physically validated before production even begins. 

0.4mm Nozzle Metal J-Head Metal 100K Thermistor Extruder 24V 1.75mm Tube Fan for 3D Printer

Weight: about 62g
For DIY remote and RepRap open source machine

Product Features

  • Extrusion head heating voltage:24V
  • Nozzle: 0.4mm 100K Thermistor Nozzle
  • Maximum speeds: 250mm / s
  • With Cooling fan, With PTFE tubing about 700mm
  • Compatible with 1.75mm filament

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3D Industries, ALUHOTEND Aluminum and Steel Metal Hotend, 1.75mm, .4mm nozzle J-Head for Prusa and other 3D Printers

The Aluminum Hotend AluhotendV5C-1.75mm is designed by the well known RepRap designer, “The Jolly Grim Reaper”, and is configured for high resolution printing with PLA, ABS and NYLON. This hotend includes a 0.4mm nozzle – though a 0.3mm nozzle is available from the manufacturer.

Plastic body (PEEK) hotends can fail when the PTFE liner swells from excessive heat. The PTFE liner can push the barrel out of the PEEK tube, forcing the heater block and nozzle to literally fall off the printer, resulting in a ruined print and a disappointed print owner. We don’t want to get rid of the PTFE liner because it serves as a non stick surface that your filament can glide over. In fact, PTFE is the same material used in most non stick frying pans. The Jolly Grim Reaper came up with a satisfying solution: keep the PTFE Liner, but replace the PEEK with an aluminum body and use a strong steel barrel that the PTFE cannot force out. As long as you configure the ALUHOTEND with a fan and avoid exceeding the recommended temperature at 245c, you should be able to reliably and consistently get high resolution prints with a minimum of fuss.

Note, this hotend requires a fan (included) blowing on the heatsink for proper operation.

Product Features

  • 1 x AluhotendV5C-1.75mm Aluminum Hotend, 1.75mm, .4mm nozzle standard J-Head
  • 100k thermistor (number 10 on the marlin firmware) with sleeves and heatshrink.
  • J-Head grove mount (aluminum)
  • 1 x 40mm 12v fan
  • 1 Heater cartridge 12v30w

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Getech Kossel Delta All Metal J-head Hotend with Line for Bowden Extruder

The Bowden principle:

The Bowden cable lets you reduce the moving mass of the extruder and thus allowing faster controlled motion, less shaking of your machine, less energy use and importantly: faster printing! Normally the mechanism that drives the filament into the hot end (where it melts) is directly on top of the extruder. This creates problems of balance and oscillations with faster motion which you can see in your printing results and hear and feel when your machine is shaking.

If the filament drive mechanism is placed on a non-moving part of the 3D printer, it can be pushed into a tube. PTFE (Teflon) is useful because it is slippery: it has little friction with the plastic.This limits wear and loss of energy. The tube’s other end is connected to the extruder’s hot-end.

The concept of using a Bowden cable as guide was suggested and pioneered by Ed Sells.

The main advantages:

All metal enables working with Polycarbonate up to 300 degrees Celsius and with future materials that require higher working temperatures beyond those supported by plastic extruders and hot end.

Tested with PLA, ABS, polycarbonate, nylon and PVA.


It is assembled with 4.7ohm 8W resistor and 100K NTC thermistor.

To make your printing easier,a 30x30mm 12VDC cooler fan is assembled for heat dissipation.

The inner diameter of the bowden feed mouth is 4mm to print with 1.75mm filament,and 6mm to print with 3mm filament.

Package Includes:

1 x assembled J-head hotend with line for bowden extruder

Product Features

  • It is assembled with 4.7ohm 8W resistor and 100K NTC thermistor.
  • To make your printing easier,a 30x30mm 12VDC cooler fan is assembled for heat dissipation.
  • The inner diameter of the bowden feed mouth is 4mm to print with 1.75mm filament,and 6mm to print with 3mm filament.

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