D3D Simple Kit Preparation

Product

1. Ship extruder wire bundle prepared, terminated, in split wire loom
2. Ship extruder parts complete, thermistor and heater tested. No tapping required, but full assy required.
   1. Easy Build Kit - already assembled and tested
3. Ship axes with motors with pulleys already on. Customer builds the axes from start to finish. Tape detail on X and Z axes.
4. Controller components are pretested for functional LCD. RAMPS assembled but without heat sinks. Motors tested. GFCI wired. Power supply tested. Endstops and probe tested.
5. Board precut.
6. Bed magnets glued
7. D3D Pro, CNC Torch Table included on SD card or USB stick.

Tools

• D3D v19.11 - production printing
• Abrasive cutoff saw - rods, aluminum heater block
• Circular saw - cutting off wood base board
• Ferrule crimper
• Soldering iron
• Wire strippers
• Razor for wire stripping
• Sidecutters

Materials

1. 3D Printing filament

Diagram

edit

BOM

edit

Kit Preparation Instructions

Extruder Wire Bundle

1. Take 6 components
   1. Probe - remove nuts
   2. Heater cartridge
   3. Thermistor
   4. Motor wire
   5. Fan
   6. Blower
2. Terminate them
   1. Put triple plug on probe
   2. Ferrule the heater ends
   3. Ferrule the blower
   4. Ferrule the fan
   5. (Nothing for thermistor and motor wire

Endstops

1. Take 2 standard endstop wires.
2. Take or trim 2 endstops
3. Repin for position 1&2 with green and red wire, cut off black wire. Green goes to lever base side.
4. Solder connections, heat shrink
5. Mount in endstop holder facing right.

Control Panel

This is after extruder is built, so we can do final testing of all components, plus motion test of 3 stepper motors.

For Distributed Quality Control, one video stream with timelapse will do.

Parts and Supplies

Parts:

1. GFCI receptacle
2. Power supply
3. Wall wort
4. USB cable
5. RAMPS with Mega
6. Screen
7. Upgrade - SSR, trigger wire, power wire to SSR,

Procedure

1. Cut off power diode on RAMPS to convert to 24V.
2. Put jumpers on RAMPS for microstepping.
3. Add stepper drivers with heatsinks
4. Upload firmware. (Set up Production Programming as the next step.)
5. Trim and strip power plug to GFCI, and tin to connect
6. Wire up power plug to 24V power supply, and tin to connect
7. Make 1 power cable from 24V power supply to 5V power into RAMPS, using ferrules and cat5 ga 22 wire.
8. Test wall wort + USB cable with Arduino
9. Connect Arduino + RAMPS + LCD
10. Plug in power to RAMPS to see if screen posts properly
11. Test extruder motor, and 3 other steppers for proper motion
12. Test heater and temp sensor - so wire connection works
13. Test fan, blower for motion - so wire connection works
14. Test endstops by homing and triggering 3 endstops manually in sequence

Printed Parts

Collect and bag printed parts:

1. Control panel
2. Extruder main
3. Extruder second side
4. Extruder lever
5. 2 Z base
6. 5 Carriage
7. ZX Connector
8. 5 Idler
9. 1 raised motor
10. 1 raised idler
11. 2 motor pieces
12. 6 pegs
13. 2 endstops

Build Instructions

1. Build axes
2. Mount extruder
3. Assemble controller with its internal wirring
4. Assemble heat bed
5. Screw down parts, using printed paper template
6. Fix wires, plug components in
7. Mount the spool holder
8. Print!

Assemble Controller

1. Connect wire to GFCI
2. Mount GFCI
3. Mount power supply
4. Mount RAMPS
5. Mount screen
6. Connect power supply to RAMPS

Production Ergonomics for 12 kits

1. Axis parts bagging, 1 hour after printing
2. Controller parts testing, 1 hr
3. Board cutting - 30 minutes
4. Extruder prep - make heatsinks- 1 hour
   1. Take 21" of stock, put jig on it to drill-mark with 3 mm bit
   2. Take off jig and drill through
   3. Tap 12 holes
   4. Cut blocks
5. File corners with disc sander (use grinder with flapper wheel)

Future Work

1. 3D Printed Modular Plug with rapid-connectable extra wires

Links

• December 2019 Production Run