D3D v20.04

Development Template

	Description	Link to Work Product	%
	DESIGN
1	Requirements + Value Proposition	[[{{{0}}} Requirements + Value Proposition]]	D3D_v20.04
2	Industry_Standards	[[{{{0}}} Industry Standards]]	{{{2}}}
3	Conceptual Design	[[{{{0}}} Conceptual Design]]	{{{3}}}
4	Module Breakdown	[[{{{0}}} Module Breakdown]]	{{{4}}}
5	3D CAD	[[{{{0}}} 3D CAD]]	{{{5}}}
6	Calculations	[[{{{0}}} Calculations]]	{{{6}}}
7	Electronics Design	[[{{{0}}} Electronics Design]]	{{{7}}}
8	Wiring and Plumbing	[[{{{0}}} Wiring and Plumbing]]	{{{8}}}
9	Software	[[{{{0}}} Software]]	{{{9}}}
	BILL OF MATERIALS
10	BOM	[[{{{0}}} BOM]]	{{{10}}}
11	vBOM	[[{{{0}}} vBOM]]	{{{11}}}
12	CAM Files	[[{{{0}}} CAM Files]]	{{{12}}}
13	Cut List	[[{{{0}}} Cut List]]	{{{13}}}
	BUILD
14	Build Instructions	[[{{{0}}} Build Instructions]]	{{{14}}}
15	Fabrication Drawings	[[{{{0}}} Fabrication Drawings]]	{{{15}}}
16	Exploded Part Diagram	[[{{{0}}} Exploded Part Diagram]]	{{{16}}}
17	Production Engineering	[[{{{0}}} Production Engineering]]	{{{17}}}
	DATA COLLECTION
18	Build Pictures and Video	[[{{{0}}} Build Pictures and Video]]	{{{18}}}
19	Data Collection	[[{{{0}}} Data Collection]]	{{{19}}}
20	Future Work	[[{{{0}}} Future Work]]	{{{20}}}

Specifications

• 12" heat bed
• 1400W heat bed
• Transitioning to OSE Universal Gearless Extruder
• Based on D3D Pro geometry

Working Doc

edit

Part Library

• 

  D3D v2004 Assembly - FreeCAD -File:D3d v2004.fcstd

• 

  Auto parallel piece. File: File:Autoparallel.fcstd File:Autoparallel.stl

Cut List

Using 3D Printer Workbench 2020:

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

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:

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.

• 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:

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