D3D Simple Kit Preparation
- 1 Product
- 2 Tools
- 3 Materials
- 4 Diagram
- 5 BOM
- 6 Kit Preparation Instructions
- 7 Build Instructions
- 8 Production Ergonomics for 12 kits
- 9 Future Work
- 10 Links
- Ship extruder wire bundle prepared, terminated, in split wire loom
- Ship extruder parts complete, thermistor and heater tested. No tapping required, but full assy required.
- Easy Build Kit - already assembled and tested
- Ship axes with motors with pulleys already on. Customer builds the axes from start to finish. Tape detail on X and Z axes.
- Controller components are pretested for functional LCD. RAMPS assembled but without heat sinks. Motors tested. GFCI wired. Power supply tested. Endstops and probe tested.
- Board precut.
- Bed magnets glued
- D3D Pro, CNC Torch Table included on SD card or USB stick.
- D3D v19.11 - production printing
- Abrasive cutoff saw - rods, aluminum heater block
- Circular saw - cutting off wood base board
- Ferrule crimper
- Soldering iron
- Wire strippers
- Razor for wire stripping
- 3D Printing filament
Kit Preparation Instructions
Extruder Wire Bundle
- Take 6 components
- Probe - remove nuts
- Heater cartridge
- Motor wire
- Terminate them
- Put triple plug on probe
- Ferrule the heater ends
- Ferrule the blower
- Ferrule the fan
- (Nothing for thermistor and motor wire
- Take 2 standard endstop wires.
- Take or trim 2 endstops
- Repin for position 1&2 with green and red wire, cut off black wire. Green goes to lever base side.
- Solder connections, heat shrink
- Mount in endstop holder facing right.
This is after extruder is built, so we can do final testing of all components, plus motion test of 3 stepper motors.
For Distributed Quality Control, one video stream with timelapse will do.
Parts and Supplies
- GFCI receptacle
- Power supply
- Wall wort
- USB cable
- RAMPS with Mega
- Upgrade - SSR, trigger wire, power wire to SSR,
- Cut off power diode on RAMPS to convert to 24V.
- Put jumpers on RAMPS for microstepping.
- Add stepper drivers with heatsinks
- Upload firmware. (Set up Production Programming as the next step.)
- Trim and strip power plug to GFCI, and tin to connect
- Wire up power plug to 24V power supply, and tin to connect
- Make 1 power cable from 24V power supply to 5V power into RAMPS, using ferrules and cat5 ga 22 wire.
- Test wall wort + USB cable with Arduino
- Connect Arduino + RAMPS + LCD
- Plug in power to RAMPS to see if screen posts properly
- Test extruder motor, and 3 other steppers for proper motion
- Test heater and temp sensor - so wire connection works
- Test fan, blower for motion - so wire connection works
- Test endstops by homing and triggering 3 endstops manually in sequence
Collect and bag printed parts:
- Control panel
- Extruder main
- Extruder second side
- Extruder lever
- 2 Z base
- 5 Carriage
- ZX Connector
- 5 Idler
- 1 raised motor
- 1 raised idler
- 2 motor pieces
- 6 pegs
- 2 endstops
- Build axes
- Mount extruder
- Assemble controller with its internal wirring
- Assemble heat bed
- Screw down parts, using printed paper template
- Fix wires, plug components in
- Mount the spool holder
- Connect wire to GFCI
- Mount GFCI
- Mount power supply
- Mount RAMPS
- Mount screen
- Connect power supply to RAMPS
Production Ergonomics for 12 kits
- Axis parts bagging, 1 hour after printing
- Controller parts testing, 1 hr
- Board cutting - 30 minutes
- Extruder prep - make heatsinks- 1 hour
- Take 21" of stock, put jig on it to drill-mark with 3 mm bit
- Take off jig and drill through
- Tap 12 holes
- Cut blocks
- File corners with disc sander (use grinder with flapper wheel)
- 3D Printed Modular Plug with rapid-connectable extra wires