D3D v19.06/fr

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Explosion

3D Explosion View - index page - https://mi_shell.gitlab.io/models_online
D3D explosion view model - https://mi_shell.gitlab.io/models_online/ose_webgl/d3d_explosion.html

Build

Build Outcomes

  1. 178C heat bed has been validated and perfected. Improvements: shortening insulated nichrome length of heating coil from 12' to 6' to facilitate threading of nichrome through insulation.

Build Notes

See D3D v19.06 Build Notes

Collaboration Areas

  1. Universal Frame Builder - parametric FreeCAD spreadsheet for designing different frame variations for the 3D Printer Construction Set, with export of DXF files. Exporting nested DXF files.
  2. Universal Axis Builder - Universal Axis Generator at the 8 mm size for variations of bolt length, belt lengths, and rod lengths; allows multiple carriages. Exports to simplified version of the axis for collaborative design.
  3. Universal Heatbed Builder - spreadsheet bed generator for varying size, heating coils, and bed support mounting. Multiple coils for energy saving can be applied.
  4. Universal Controller Builder - Universal Controller of different sizes for different size frames, and for varying the number of components such as relays, analog controllers, and other components of choice.
  5. 3D Printer Product Strategy

Critical Path

  • This is Distributive Enterprise Release Candidate.
  • Rationale - go to 120V heat bed to reduce power supply size.
  • Don't include TMC2130 initially as that will take time to optimize, even though it gets rid of the end stops. Use TMC2208 now.
  • Include clean wiring
  • Include 3D printed corners

Goals:

  1. Building new heated bed allows for a high performance printer
  2. With 3D Printed control panel, electronics become simpler for builds
  3. Silent operation is a good upgrade

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Collaboration

CAD

HintLightbulb.png Hint: Tasks: (1) Updating Y axis holding bracket including 3D printed Corner Fit. (2) New insulated bed. (3) 3D Printed Control Panel. (4) Offset cable chain start piece. Finalprinter1902.png


Printer

Design Rationale:

  • 0.26 diameter hole through frame (6.6 mm) and through Y mount to frame

Framev1902.pngZ1D3Dv1902.pngAxis half carriage.pngFrame+axes.pngFrame+axes+extruder.pngXy bracket.pngFinished v1902.pngRaisedbed.pngWithcablechain.pngEndstopholder2.pngCablechainbracket.pngXy bracket hole.pngLimitswitch.pngEndstop assy.pngE3dtitanbracket.pngFramebracket.pngXcable.pngYcable.pngFinalprinter1902.pngNewymountbracket1904.pngNewymountbracket2 1904.pngNewymountbracket3 1904.pngChainoffset.pngSecond cable holder.pngSpacer.pngPeg85.jpg

Itemized:

  1. Frame
  2. Carriage
  3. Motor piece
  4. Idler piece
  5. Half-carriage with regular bearings
  6. Rods
  7. Extruder
  8. Endstop
  9. Heated Bed
  10. Cable chain start, simplified
  11. Cable chain end, simplified
  12. Cable chain link, simplified
  13. 18 mm bolt
  14. 30 mm bolt
  15. Angle for holding X to Y axis
  16. Controller - power supply - borrow from Lyman Filament Extruder
  17. Controller - Arduino
  18. Controller - RAMPS
  19. Controller - LCD screen - reverse engineer from drawing?
  20. Controller - MOSFET

Control Panel

See more at 3D Printer Control Panel

Framev1902.pngPowersupply v1904.pngRAMPS14 v1904.pngStepperdriver v1904.pngSsr v1904.pngSmartcontroller v1904.pngGfci v1904.pngControlpanel v1904.pngControlpanel+frame v1904.pngControlpanel+panel v1904.pngControlpanelproper v1904.pngControlpanelwithmounts v1904.pngWirecover v1904.pngPanelonly v1904.pngBentpanel v1904.pngHeatbed wirelock.pngFinalcontrolpanel.pngOntrolpanelseated.png D3DPlugInner.png D3DPlugCover.png

Heatbed

Framev1902.pngHeatbed snapbuckle.pngHeatbed1 body1904.pngHeatbed perf1 body1904.pngHeatbed standoffs body1904.pngHeatbed perforated.pngHeatbed wirelock.png

Frame

Framev1902.pngSpacer v1914.png

Extruder

Nozzleassembly.pngCarriageintegratedbracket.pngExtruderspacer.png


Build Instructions

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Frame Build

Control Panel Build

Plug

Heatbed

Current heatbed uses 16 ga steel plate, and the print surface is 1/8" steel plate with PEI surface on top cut to size, attached with 3M double-sided adhesive. The max continuous temperature of this heatbed is 178C, and it heats up faster than the extruder. It overshoots temperature when cycling to set point, which still works but can be tuned. Standard print bed setting was 80C. When attaching the thermistor, insulate it from the nichrome heater so it reflects more the temperature of the print surface, not the heater element. More heatbed build pictures in Google Folder - [13]

More pictures from STEAM Camp 2019 -

BOM

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Printed Parts

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v19.06 BOM Details

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Parts

  • SSR -
  • GFCI - [14]
  • Power Supply - [15]
  • Nichrome wire 26 ga 12' - [16]
  • Fiberglass sleeve - [17]
  • Crimps
  • Spade terminal brass -

3D Printed Files and Production Engineering

  1. Check.png[8] Frame Corners - File:Framebracket.fcstd. 1 - File:Framebracket.stl. 8 - File:8corners.stl - 4:51 hr + 73 g PLA.
  2. Check.png[1] Control Panel - File:Controlpanel v1904.fcstd. 1 - File:Bentpanel v1904.stl - 7:28 hr and 111 g PLA.
  3. Check.png[4] Short carriage - File:Axis half carriage.fcstd. 1 - File:Axis half carriage.stl - 45 min 10 g PLA. 4 - File:4 Axis half carriage.stl - 2:41 hr, 40 g PLA
  4. Check.png[6] Carriage - File:Universal axis carriage side.fcstd. 1 - File:Universal axis carriage side.stl - 1:14 hr, 18 g PLA. 6 - 6 Carriages for printing - 7:26 hr + 108 g PLA
  5. Check.png[1] Offset Cable Chain - File:Offsetcablechain.fcstd. 1 - File:Offsetcablechain.stl. 18 min + 4 g PLA.
  6. Check.png[1] Sensor Holder - File:Nozzleassembly.fcstd. 1 - File:Nozzleassembly.stl - 1:01 hr and 14 g PLA
  7. Check.png[1] Extruder Mount Integrated Into Carriage - File:Brackettop.fcstd. 1 - File:Brackettop.stl. 1:12 hr + 18 g PLA.
  8. Check.png[1] Plug Top - File:D3DPlugCover.fcstd. 1 - File:D3DPlugCover.stl. 18 min + 5 g PLA.
  9. Check.png[1] Plug Bottom - File:D3DPlugInner.fcstd. 1 - File:D3DPlugInner.stl - 13 min + 3 g PLA.
  10. Check.png[2] Endstops - File:Endstopholder2.fcstd. 1 - File:Endstopholder2.stl - 7 min 2 g PLA. 2 - File:2 endstops.stl - 13 min 4 g PLA.
  11. Check.png[2] XY bracket with hole - File:Xy bracket.fcstd. 1 - File:Xy bracket.stl - 2nd in history - 40 min 10 g. 2 brackets with hole - File:2 xy bracket.stl
  12. [2] Y Axis Mount bracket - pair of them - File:Y mount bracket.stl. For source, see above line.

More

  1. [10] Idler Piece - File:Universal Axis Idler Side short version.fcstd. 1 - File:Universal Axis Idler Side short version.stl. 10 - File:10 idler pieces.stl
  2. [10] Motor Piece - File:Universal axis motor side.fcstd. 1 - File:Universal axis motor side.stl. 10 - File:10 motor pieces.stl
  3. [50] Cable chain - File:Link.fcstd. 1 - File:Link.stl. 42 - File:42 cablechain.stl
  4. [2] Cable chain end - File:D3dcablechain end.fcstd. 1 - File:D3dcablechain end.stl. 2 - File:2 cablechain end.stl
  5. [1] Control Panel Wire Cover - File:Wireboxcover v1904.fcstd. 1 - File:Wireboxcover v1904.stl
  6. [1] Extruder Bracket - File:E3dtitanbracket.fcstd. 1 - File:E3dtitanbracket.stl. 10 - [[]]
  7. [2] Y-Axis Bracket - [[]]. 1 - [[]]. 10 - [[]]
  8. [10] Belt Peg - File:Peg 8mm rods.fcstd. 1 - File:Peg 8mm rods.stl. 10 - File:10pegs.stl - 6 large, 4 small.
  9. Spool holder

Production Engineering

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Wiring

See also Universal Controller

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Testing MTA-100 Connectors

Shopping list from Digikey:

Mta100digikey.png

Heated Enclosure

Heated Chamber

Prior art - see Heated Build Chamber Patents

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Quality Control, Troubleshooting, and Repair

So now you have built your machine and controller. Now here is how to make it work as expected, going through an exhaustive list of potential issues, prior to cleaning up all the wiring.

Quality Control

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Suggested Bulk Procedure

  1. Test that power lights on all power supplies
    1. For faulty power supply, connect to the back terminals?
  2. Wires for the power supply to RAMPS - one line for 12V, 2 lines for 24V. Prevents wiring mistakes.
  3. Use ferrules on wires, and only one wire per clamb-down terminal. If multiple, join them elsewhere.
  4. Clear wiring labels
    1. Extruder fan - 1 line on red/black wire
    2. Print cooling fan - 2 lines on red/black wire - or use different color wire
    3. Extruder heater block- should be high t wire, different than others.

Troubleshooting Guide

Covers:

  1. Power supply power cable issues

Cleaning Up the Wiring

The final wire routing should look like this on the control panel:

  1. All wires tight and out of the way
  2. Any wire that is too long is pulled behind the Control panel or near the cable chain and zip tied neatly to other wires or fixing points.
  3. All wiring is kept accessible for repairs and upgrades
  4. A shield is placed in front of the power supply to prevent any shocks.
  5. Wires from stepper motors are hidden along the corners of the frame
  6. Stepper motor wires are oriented so that the closest path to the control panel results.

Code

Printer Profile in Lulzbot Cura for OSE D3D v19.06

Bugs

  • Windows version software toolchain needs full documentation
  • OSE Linux needs updating with latest Cura and FreeCAD
  • OSE Linux instructional for making ISO needs updating
  • Discourse needs to be set up for Development discussion
  • Askbot needs to be set up for customer support (and development)

Links

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