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