D3D v20.04: Difference between revisions

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Revision as of 05:17, 20 April 2020

Developent Template

D3D v20.04
Description Link to Work Product %
DESIGN
1 Requirements + Value Proposition D3D_v20.04 Requirements + Value Proposition {{{1}}}
2 Industry_Standards D3D_v20.04 Industry Standards {{{2}}}
3 Conceptual Design D3D_v20.04 Conceptual Design {{{3}}}
4 Module Breakdown D3D_v20.04 Module Breakdown 20
5 3D CAD D3D_v20.04#3D CAD 20
6 Calculations D3D_v20.04 Calculations {{{6}}}
7 Electronics Design D3D_v20.04 Electronics Design {{{7}}}
8 Wiring and Plumbing D3D_v20.04 Wiring and Plumbing {{{8}}}
9 Software D3D_v20.04 Software {{{9}}}
BILL OF MATERIALS
10 BOM D3D_v20.04 BOM {{{10}}}
21 BOM Optimization D3D_v20.04 BOM Optimization {{{21}}}
11 vBOM D3D_v20.04 vBOM {{{11}}}
12 CAM Files D3D_v20.04 CAM Files {{{12}}}
13 Cut List D3D_v20.04 Cut List {{{13}}}
BUILD
14 Build Instructions D3D_v20.04 Build Instructions {{{14}}}
22 Quality Control Checklist D3D_v20.04 Quality Control Checklist {{{22}}}
15 Fabrication Drawings D3D_v20.04 Fabrication Drawings {{{15}}}
16 Exploded Part Diagram D3D_v20.04 Exploded Part Diagram {{{16}}}
17 Production Engineering D3D_v20.04 Production Engineering {{{17}}}
DATA COLLECTION
18 Build Pictures and Video D3D_v20.04 Build Pictures and Video {{{18}}}
23 Troubleshooting and Repair D3D_v20.04 Troubleshooting and Repair {{{23}}}
19 Data Collection D3D_v20.04 Data Collection 15
20 Future Work D3D_v20.04 Future Work {{{20}}}

Specifications

Working Doc


edit

3D CAD

D3d v2004.pngWithsidehole.pngFattened.pngAutop.pngNewbedholder.pngNewbedholder2.pngNewbedholder3.pngPanelholder.pngEndstopstopcombo.png

Cut List

Using 3D Printer Workbench 2020:

  1. X - [2] 22”
  2. Y - [4] 21”
  3. Z, bed, spool holder - [9] 17”

Firmware

  • Firmaware goes back from the 2-wire endstops to 3-wire endstops with indicator light to make fabrication easier. File:Marlin D3D Pro v1.0.zip no longer works.
  • New firmware builds upon the last version with 3-wire endstops - from 3D Printer Genealogy - the first version that had 2-wire endstops was D3D v19.02. Change log from v19.12 firmware states " Change log: endstop_reversing was reversed on X and Y compared to former versions". Thus, chaning this only would suffice - reversing back to the opposite of File:Marlin D3D Pro v1.0.zip
  • New file: File:Marlin D3D Pro 2.zip

Heater Element

(See Nichrome Calculator)

Notes:

  • Fiberglass sleeve used - HTG fiberglass, does not fray like standard high temperature sleeving (1000F) and is rated for . See [1]. Note that the resin can burn out at the 650C (1200F) workign temp. Sleeve has VW-1 flame resistance. Made of fiberglass, it does not burn out, but may fuse and lose fiber structure.
  • Inner core: 5' long wraparound of 2mm tight braid fiberglass sleeve - 600C - [2]. Started with 5', wrap was more like 4' long.
  • This is packed into 4' of 6 mm tight braid fiberglass sleeve.
  • Fence wire is used to couple 200C wire to nichrome, in order not to burn out 200C wire. Nichrome is wrapped around the fence wire 5-10 turns
  • Copper wire is soldered to the fence wire.
  • 10" end piece of 6 mm tight braid sleeve covers the 200C wire, fence wire, and ends of nichrome.
  • 2 strands of nichrome heater element are made, each 14' long, each about 600W.
  • Ends, covered by 6 mm tight braid sleeve - stick out the finished bed. Third wire set is the thermistor, which is wrapped with 2 mm tight braid so it doesn't melt out.

Heater Optimization

Theoretical idea:

D3d2004nichromecalc.png

But, ga 18 can't bend easily using a cordless drill.

  • 20 feet of 20 ga wire appears to be most convenient - 1 piece, max at 1200F. Current 500W heater is 1200F max, and works well.

2020.png

  • 14 feet of 24 ga works perfectly by hand to get a good wrap over 4 feet, and goes fast, about 1 minute pending tieups:

Actualwrap.png

Heater Element Wrapping Procedure

  1. Cut 14' of ga 24 nichrome
  2. Cut 5' of tight 2 mm fiberglass sleeve
  3. start the wrap of nichrome on one end of sleeve
  4. Attach other end of sleeve to a free-spinning rotor
  5. Once enough to go inside a cordless drill chuck - grab the nichrome wrap and turn on the drill in reverse to start wrapping. Tension the sleeve against the rotor
  6. Wrap away! A person should be able to wrap 4 feet long just by holding a cordless drill