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(WORKING) Nicks-Fix "Continuous IPA Filtration" system

The alcohol used to wash UV resin printed parts can get slimy as snot in no time at all; fortunately for me this issue now has a solution!

The "Who"

Nick Wilson of the Youtube channel https://www.youtube.com/@nicks-fix posted a video about a new Continuous IPA Filtration system he had created.  The breakthrough for me was seeing someone pair up the cheap water filters I had already rejected with an alcohol safe diaphragm pump to handle the pressure needed to use those cheap filters!  (...and WHY didn't I think of that?)

Resin Printer Mods and Continuous IPA Filtration!

https://www.youtube.com/watch?v=DfM1CXBOZns

The Basics
  1. Expose the resin containing alcohol to a UV light source
    • Creates a suspension of tiny & hard to remove plastic particles within the alcohol
  2. Separating out these miniscule plastic bits is harder than one might expect
    • Nick's design used a diaphragm pump to push this nasty alcohol solution through some easily changeable water filters

Background

I have made many unsatisfactory attempts to reclaim some usable alcohol from the resinous sludge left behind after washing resin prints.  The only reliable solution found to date is exposing the mix to UV light, which fortunately & unfortunately hardens each super tiny dissolved particle of resin, creating a nearly gel like consistency plastic/alcohol solution that is not fun to separate.

    • Cheese cloth - Soaks up the alcohol and can be wrung out to squeeze and separate the solids out
      • LOTS of time and effort splashing contaminated alcohol around
    • Filter paper - Clogged almost immediately and didn't really trickle through even over time as I expected
      • No additional drips in a sealed container for a month and it lost more to evaporation/condensation inside the box
    • Cotton cloth - Used to "wick" from higher "dirty" container to lower "clean" container, but too slow for my taste
    • Waiting - Settling out solids takes longer than I am willing to wait since 90 days was not even a start!!!
    • Vacuum filtering caused far too much loss of alcohol with my setup (I'm clearly not a chemist)

I chose not to use alum or other chemical additives to aid in the precipitation of particles out of solution.  The final part's reliability is worth more to me than the risk of adding other chemicals with unknown sensitivity to the original resin.

The "What"
  • Silicone tubing - flexible and mostly resistant the these specific chemicals
    • Gets alcohol from dirty container through the UV exposure and into the filters
    • Returns the cleaner alcohol back into a clean container
    • OR could be used to simply recycle from and to the same container making it progressively cleaner
  • Hose barbs - hollow threaded fitting with a nozzle for the hose to slide over
    • Connects filters or pump to the silicone tubing
  • Plumbing Nipples - Hollow tube with threads on each end
    • Connects filters to each other
    • Connects pump to filter
  • Diaphragm pump - Liquid pump capable of moving alcohol without degradation
    • Santoprene diaphragm resists alcohol and resins 
    • Pushes our alcohol through the system
  • Double 10" x 2.5" water filter elements - 5 micron & 1 micron stages
    • 5 micron leaves particles that are too large, but also don't clog as quickly
    • 0.5 micron appears to be getting all the particles we can see
  • UV LED strips or other strong UV source
    • 405nm is ideal but close is probably close enough


The "How"

...

The "Why"

Nick's continuous filter system enables me to run resin prints through my wash and cure station without additional alcohol rinses.  

  • Time savings
    • My previous workflow (15 minute minimum):

      1. <1min - Parts have already been dripping for at least a few minutes, Tilt parts 45 degrees and drip for another few minutes
      2. <2min - Rinse in gooey slimy alcohol to get most of the excess resin off (Nasty alcohol)
      3. <variable> - Remove supports
      4. <2min - Run through a 30 minute wash cycle (medium cleanliness alcohol)
      5. <5min - Hand spray with New alcohol (unused alcohol)
      6. <5min - Dry with compressed air

    • New workflow (8 minute minimum):

      1. <1min - Parts have already been dripping for at least a few minutes, Tilt parts 45 degrees and drip for another few minutes
      2. <variable> - Remove supports
      3. <2min - Run through a 30 minute wash cycle (clean? alcohol)
      4. <5min -Dry with compressed air
  • Easily changeable filters
    • These water filters are fairly easy to change without getting contaminated alcohol everywhere
    • Replacement filters are reasonably priced at local hardware stores

 

  • Better overall use of resources
    • Isopropyl alcohol requires boiling for it's concentration/creation while the activated carbon in a 5 micron filter is a (nearly) free by-product of many other processes
    • Distilling 1 US Gallon of water/alcohol costs roughly 0.5kWh of energy minimum

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