3D Printer Production Engineering 2018
Contents
Working Doc
Oct 2019
Hint: Note that Angle Corner of late October has superseded the 3D printed corners File:Framebracket.fcstd and is the preferred way to go for a simpler frame design which avoids bolt holes.
Feb 2019
Priorities
Now
Goal is to get ship-ready in units of 12
- Build D3D Wire Box.
- Redo production engineering of endstop holder for cleanup-less printing
- Develop Electronics Quality Control
- Do materials organization design for 12 printers - production engineering
- Do Kit Build Procedure
- Design Tooling Box for kits
- Do new BOM
- Do precision test - print 3D Printed Calipers
- Do workflow Design
- Redo 3D printed part production engineering for 0.8 mm nozzle (or possibly greater) (note this doesn't work well in the cold, so would need a thermal enclosure.
- Transition to 24V system (next production run)
- Transition to Silent Stepper Drivers for RAMPS
Later
- Evaluate cost of DIY heat plate, 1/8" steel. See Nichrome Wire.
- Do 12" bed printer - need for efficiency of simple production engineering with flats as feedstock
Tooling Pack
- Dental pick
- 6 mm driver, small flathead, Philips bit
- Nozzle wrench
- See included accessories for Lulzbot [1]
Range of Motion
- Limit in Y1 is determined by bracket piece interference - modify bracket
Quality Control
- Parallel of Y axis - automatic
- XY right angle correction - via physical stops on X Axis, or via modified calibration routine in firmware. For Y homing, we can use modified procedure where we home Y, then max out at the physical end of motion to even out axis, and then home Y again. This would require digging in Marlin.
Quality Control
- Parallel of Y axis - automatic
- XY right angle correction - via physical stops on X Axis, or via modified calibration routine in firmware. For Y homing, we can use modified procedure where we home Y, then max out at the physical end of motion to even out axis, and then home Y again. This would require digging in Marlin.
Wiring
- Source quality controlled cables. Avoid repinning.
- Get wire terminations for the terminal block of small wires
Stepper Drivers
- TMC2130 stepper Drivers are quiet - see Lulzbot - [2]
Cable Chain
- Modify start cable chain piece for offset hole if using large stepper
PEI
- Paper cutter for manual cutting
- Or could be bought in the right size
- Possibly 4W laser cutter?
- Milling with D3D CNC Circuit mill, but requires a magnetic holder mechanism (or suction table) that is as simple as a 3d printed magnet holder with 4 magnets with these holders on a 1 foot grid and away from the toolpath so tool doesn't hit. Solid metal plate as base would do it, with software that addresses material height. With fixed bed, auto level would not need to be done every time - just once in a while or for different tools. For milling, underlayment must be used, such as paper, which is sacrifcal. With high precision, we could also use limited backing material, such as thin cardboard.
Extruder
- Small driver for small Allen heads should be a small power tool.
- This tool should be 3D printed.
Sensor/Fan Mount
- To use existing bolts, bolt hole closer to sensor must be 2 mm thicker for screw to lock down on it without washer.
- Fan wire extension was 34"
- Get rid of lip inside sensor holder - for full adjustability of sensor height
Top Carriage
- Extruder mounting bolts must go above frame. ROM is limited otherwise.
Nozzle
- Nozzle needs to ride above frame to not risk breaking it off.
- Bed must raise slightly?
Short Carriage
- Limits the depth of belt peg insertion.
- Belt peg needs optimization. Can shorten peg. Right now 90% goes all the way in and 95% goes in more than half way.
Notes
- Do not use E3D instructions for heat tightening, they are wrong for the OSE case. They lead to re-do of heat tightening in most cases. I added MJ Comment on Heat Tightening at the Titan Aero build instructions at https://e3d-online.dozuki.com/Guide/Titan+Aero+Assembly/23.
Heat Tightening
- For heat tightening a number of extruders at once - a 30A power supply can support up to 9 heater blocks at one time (360W) pushing the supply to the limit. Good idea may be to have a jig: just a power supply to make connection easy - ideally plugging 6 heater blocks at a time, and disconnecting one as soon as we are done with it and connecting the next one in line. This eliminates heatup time. At the same time, a RAMPS should be available to test that the thermistor is working, where 2 thermistors (extruder + bed) could be plugged in at one time. So you could cycle through all of them. Heat tightnen one after another. After initial heating (several minutes) - heat tightening should take a minute per nozzle - one right after another. Here, would going to 24V system help? Not sure, as power is power.
Kits
Based on the notes at Kit Certification - there is a significant value proposition behind distributed production of 3D printer kits based on the OSE 3D printer design.
Our unique value proposition that enables distributed production is that one can build our printer from common, off-the-shelf-parts - and attain industrial performance. This is not the same as Prusa (OS?, Lulzbot (OS), or Jellybox (FOS) - 3 leading printers.
The question remains if distributed quality control can succeed in producing high quality products in a distributed fashion.
