D3D Pro v23.12 Development Timeline
Abridged Timeline:
- Build one printer to lock in the version
- Complete Kit Certification
- Complete CAD
- Build another 1-2 printers
- Complete kit build guide
- Complete kit prep guide
- Complete development template
- Create marketing materials
- Create presentation
- Create website
- Make workshop announcement
- Source kits as orders come in
- Prep kits
- Run amazing event
- Just when you think you're done, you've only just begun :)
Full Timeline:
CAD New Work
- Model frame for 1/2" rebar
- Model corner connectors / Y axis holders 8hrs
- Model Z axis top and bottom holders 4hrs
Preliminary BOM + Sourcing
- Use the BOM from D3D Pro v20.07
- Make changes for rebar frame 15min
- Make changes for halogen heat bed upgrade 1hrs
- Order all parts 4hrs
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 (normally closed)
- 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
- Gather all materials 1min
- 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
- Add 4 vertical rebar pieces into one of the square's corners 2min
- Tighten fasteners
- Put second square onto the top 2min
- Turn frame onto its side
- Use jig to square
- Tighten fasteners
- Done!
- Build Universal Axes
- Notes
- Build the axes all identically first with all screws tight
- The Y and Z carriages should come with a arrow on them that should point toward the motor side when correctly assembled. (Distributed Quality Control)
- Build all axes in parallel so that each step is performed on all five axes before moving to the next step. (allows for better swarming)
- Notes
- Tape linear bearings with electrical tape to make proper tightness on rods and fit in carriages (20 total?) 10min
- Include knife in kit of supplies
- Test tightness of fit by sliding bearing over smooth rod - falls slowly
- Install linear bearings in every carriage 4min
- Tighten fasteners
- Add GT2 gears to 5 stepper motors 5min
- Install stepper motors on motor sides. 5min
- Install flanged bearings and bolt/nut into idler side. 2min
- Install all rods into motor sides 5min
- Tighten fasteners
- Install carriages onto rods 2min
- Be mindful of installation direction of carriages relative to motor side.
- Arrow should be on same side as motor, pointing toward motor :)
- Install Idlers on rods 5min
- Tighten fasteners
- Measure and cut GT2 belt 8min
- Install belt peg on one end of all five belt lengths 3min
- Install belts 15min
- Start by installing in carriage
- Loop through motor side
- Through second carriage side
- Through idler side
- Back through carriage again
- Put on belt pinch at overlap and tighten loosely
- Adjust axis lengths for X and Z 5min
- Adjust X Axis rod offsets with rods jutting past the motor and idler sides
- Y Axes with unique carriages
- Z Axes with shorter rods
- Build Universal Extruder
- Put Mk7 drive gear on stepper motor 2min
- Screw in stepper motor 2min
- Screw on side attachment 2min
- Screw together hot end assembly 5min
- Install height sensor 1min
- Install hot end and heat block 2min
- Build Heated Bed
- Make an X from corner to corner of 1/8" bed plate to find center. 1min
- Attach long nut to bed plate via high temperature epoxy 2min
- Solder together halogen light heaters in series 2min
- Install halogen lights into holders 1min
- Install carbon fiber blanket 1min
- Tape thermistor inside of metal tube 1min
- Install metal tubes 1min
- Install halogen lights 1min
- Install carbon fiber blanket strips 1min
- Screw together bed 1min
- Done
- Build Universal Controller
- Tin all wires 30min
- Attach all components to panel with Zip ties 8min
- Build filament holder
- Three rods and two plastic bits :) 1min
- Final Assembly
- Attach axes to frame
- Attach filament holder
- Attach extruder to X Axis
- Attach controller
- Attach all wires from controller to other modules
- Hot tighten hot end
- Run test print
- Done!
Perform Kit Certification
Create and finalize LOD500 cad
- 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
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
Documentation is workshop ready at this point
Create website
Create marketing materials
Make workshop announcement
Source kits as ticket orders come in
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