D3D Pro v23.12 Development Timeline

Timeline to workshop ready point:

(Does not include marketing/workshop stuff, just kit documentation prep)

Create and finalize LOD500 cad

• Model frame for 1/2" rebar
  • Model corner connectors / Y axis holders 8hrs
  • Model Z axis top and bottom holders 4hrs
• Model heated bed components and assemble
  • Buy halogen bulbs and holders to take measurements .5hr
  • Model halogen holder and bulb 1hr
  • Model heated bed tubes .5hr
  • Model heated bed sheet metal (including holes) .5hr
  • Model heated bed carbon fiber blankets .5hr
  • Assemble heated bed in CAD 2hr
• Assemble extruder in CAD from available prior work 4hrs
• Assemble control panel in CAD from available prior work 4hrs
• Assemble axes from available prior work - Done

Generate BOM from CAD - Instant in FreeCAD 21

• Find multiple vendors for each part 12hrs

Source and order all of the first kit supplies

• Order parts from multiple sources to vet quality/compatibility

Prep the first kit

• Print 3d printed components - 48+ hrs
• Cut rods and rebar to size - 1.5hr
• Cut lengths of belt - 15min
• Cut lengths of pipe for bed - 30min
• Cut plates for bed (if necessary) - 15min
• Cut aluminum heatsink to size - 10min
• Machine aluminum heatsink on drill press - 15min
• Test all electrical components (motors, endstops, RAMPS+Mega, bed heater, etc) 30min
  • Motors all spin
  • Endstops trigger properly and are correct type for failing safely
  • Bed Heater - lighting up
  • Hotend and thermistors - Heat up and measure temp
• Heat gun the control panel print as in 4D Printing 5min

Build the first kit

• Build Universal Frame
  1. Gather all materials 1min
  2. Build two squares from the corners and rebar 10min
     • Use jig to square (wooden dowel cut to length of connector distance)
     • Be mindful of corner direction
     • Tighten fasteners
  3. Add 4 vertical rebar pieces into one of the square's corners 2min
     • Tighten fasteners
  4. Put second square onto the top 2min
     • Turn frame onto its side
     • Use jig to square
     • Tighten fasteners
  5. Done!
• Build Universal Axes
  • X Axis with rods jutting past the sides
  • Y Axes with unique carriages
  • Z Axes with shorter rods
• Build Universal Extruder
• Build Heated Bed
  • Primarily assembled using high temp epoxy
• Build Universal Controller
  • Tin all wires
  • Attach all components to panel
  • Follow prior art wiring plans
• Build filament holder

Perform Kit Certification

Assemble another printer, taking pictures of every step and recording the steps taken in order.

Create documentation for printer, following wiki development template

• Kit Prep Manual
  • Safety, workspace layouts, kit prep expected effort timeline
  • Sourcing section - notes on finding local substitutes
  • Metal Cutting Section
  • Aluminum Heatsink Prep Section
  • Steps for partial preassembly
  • Packaging for workshop
  • Packaging for shipment
• Build Manual
  • Universal Frame Section
  • Universal Axis Section
    • X, Y, and Z are separate
  • Universal Extruder Section
  • Fast Heated Bed Section
  • Universal Controller Section
  • Final Assembly Section
  • Wiring and testing Section
  • Troubleshooting Section

Have an assistant assemble a kit from documentation alone to test for weaknesses

• Revise documentation as necessary for clarity, ease of assembly, turnkey-ness

Prep the workshop kits

• Print 3d printed components
• Order parts
• Cut rods and rebar to size
• Cut lengths of belt
• Cut lengths of pipe for bed
• Cut plates for bed (if necessary)
• Cut aluminum heatsink to size
• Machine aluminum heatsink on drill press
• Test all electrical components (motors, endstops, RAMPS+Mega, bed heater, etc) for all kits
• Gather together kits per BOM
• Label parts as labeled in the documentation (aiming for eventually offering language agnostic assembly instructions)
• Package kits in separate crates/boxes for easy transport to event
• Print out documentation binder - 1 per kit
• Prepare OSE Linux Live USBs - 1 per kit