Elements & Components

I´m a great fan of the concept “FABLAB 2.0” in which any FabLab can replicate itself. Especially for Brazilian context, a country full of creative people, lots of opportunities but limited resources. São Paulo is the major city with a great entrepreneur ecosystem, since we started Insper FabLab back in 2014 there is a growing demand for projects, prototyping and small batch production. For that, I can certainly tell that funds and machinery costs represents one big barrier for Makers to jump in to production.

Final Project

  • Concept
  • Sketch
  • Design

Inicial Concept

The challenge is to replicate a typical FabLab machine from scratch using Insper FabLab machines and tools. I choose to make a Delta printer (we don´t have those models here in Brazil) and experience the process of prototyping it from the sources avaliabe in Insper Fablab.

The first concept is based on Reprap Rostock Open Source project, but the idea is to make it bigger! The goal is to build a MVP - minimum specs and make it work, from that work on upgrades like dual extruder or a exchangeable modular tool for cutting, drawing, measuring or other functions.

Sketch

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Aesthetic Design

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The Prototype

Progress Bars

Structure

100% Complete

Power

95% Complete (can be upgraded)

Actuators (DirectDrive)

70% Complete - It works but sometimes the Pinion get stuck

Print Head + Effector + Arms

85% Complete (need more testing)

Heated Bed

99% Complete (but good to go)

Electronic and sensors

90% Complete (Hide cabling)

User Interface

70% Complete (danger)

LogBook

(Feb/01) First CAD Designed prototype - going for structural aluminum profile 30x30 T-SLOT frame.

(Feb/08) Aluminum profile cutted to project size parts and assembled. Looks gorgeous !

(Mar/01) First setup with a recycled computer PSU - 550W "Hacked" to a power Hub.

(Mar/29) Working good, solid 12V supply with motors and Heat Bed On. But I´m planning to upgrade and test 24V to the Heat Bed and "overpower" the step mottors to 16v and get extra torque

4x Classic NEMA23 step motors - 4kgf for the first run !

Update 1 - going for nema 17 1,5kgf as they are smaller (afraid of momentum) and the combined torque from Delta configuration should do the task!

Update 2 - Build the Direct Drive coupling, mottors are running but the pinion get stuck sometimes

Update 3 -

Doing it !

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Bil of materials (BOM)

Lessons Learned

Testing motors and DirectDrive: