D3D Pro v23.12 Development Timeline

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Abridged Timeline:

  1. Build one printer to lock in the version
  2. Complete Kit Certification
  3. Complete CAD
  4. Build another 1-2 printers
  5. Complete kit build guide
  6. Complete kit prep guide
  7. Complete development template
  8. Create marketing materials
  9. Create presentation
  10. Create website
  11. Make workshop announcement
  12. Source kits as orders come in
  13. Prep kits
  14. Run amazing event
  15. 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
    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
    • 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)
  1. 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
  2. Install linear bearings in every carriage 4min
    • Tighten fasteners
  3. Add GT2 gears to 5 stepper motors 5min
  4. Install stepper motors on motor sides. 5min
  5. Install flanged bearings and bolt/nut into idler side. 2min
  6. Install all rods into motor sides 5min
    • Tighten fasteners
  7. 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 :)
  8. Install Idlers on rods 5min
    • Tighten fasteners
  9. Measure and cut GT2 belt 8min
  10. Install belt peg on one end of all five belt lengths 3min
  11. Install belts 15min
    1. Start by installing in carriage
    2. Loop through motor side
    3. Through second carriage side
    4. Through idler side
    5. Back through carriage again
    6. Put on belt pinch at overlap and tighten loosely
  12. 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
  1. Put Mk7 drive gear on stepper motor 2min
  2. Screw in stepper motor 2min
  3. Screw on side attachment 2min
  4. Screw together hot end assembly 5min
  5. Install height sensor 1min
  6. Install hot end and heat block 2min
  • Build Heated Bed
  1. Make an X from corner to corner of 1/8" bed plate to find center. 1min
  2. Attach long nut to bed plate via high temperature epoxy 2min
  3. Solder together halogen light heaters in series 2min
  4. Install halogen lights into holders 1min
  5. Install carbon fiber blanket 1min
  6. Tape thermistor inside of metal tube 1min
  7. Install metal tubes 1min
  8. Install halogen lights 1min
  9. Install carbon fiber blanket strips 1min
  10. Screw together bed 1min
  11. Done
  • Build Universal Controller
  1. Tin all wires 30min
  2. Attach all components to panel with Zip ties 8min
  • Build filament holder
  1. Three rods and two plastic bits :) 1min
  • Final Assembly
  1. Attach axes to frame
  2. Attach filament holder
  3. Attach extruder to X Axis
  4. Attach controller
  5. Attach all wires from controller to other modules
  6. Hot tighten hot end
  7. Run test print
  8. 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