Unfortunately, this final project really begun when the Fab Academy 2013 was close to finish. Initially, I had another project in mind but I decided to leave it for some reasons. Since then, I have worked in a very ambitious project: Design and build a new 3d printer machine (FDM technology).
The goal is to get a strong, durable, reliable with easy maintenance requirements 3d printer to work intensively in any fablab environment. Because the portability is not a requirement at this stage, the weight is neglected, except for the moving mechanical devices.
I decided to work in structure, mechanical devices, software and some hardware adaptation, etc.
What will it do?
This 3D Printer machine might integrate any FabLab and will be a strong and reliable low cost machine with easy maintenance requirements.
It will be used to materialize digital 3D models by fused ABS or other polymer with fusion point below 250 ºC.
Who's done what beforehand?
There are many more 3D printers models, called "low cost" but they use a lot of plastics and imprecisions that compromises the successes of some more accurate tasks. One purpose of this 3D printer is to be more "heavy duty" than the other machines, other important requirement it is to have easy maintenance.
To work on structure, mechanical devices, software adaptation, electronics and wiring, casing and logos, etc. I will use and develop a lot of skills, most of them acquired within the Fab Academy course as well on the awesome fab network. I shall endeavour to ensure that I give my contribution for this amazing "learning by doing" process.
What materials and components will be required? And where will they come from?
The project will require:
| What materials and components will be required? |
where will they come from? |
| A few tubes of aluminum (standard aluminum profiles to make windows and doors) |
Local supplier |
| Technical aluminum profile (bosch rexroth) and hammer-head nuts |
Local supplier (Manutrial-Guarda) |
| Fiber carbon sandwich (I need to machine it and make some strips to finish the edges...) |
My sponsor have it in warehouse |
| ABS fillament |
Fablab |
| Srews (M3 & M4), spings, nuts, washers |
Local supplier (Oxibeiras) |
| Bearings |
Robotdigg |
| Electronics (main controller, motors and drivers) |
Robotdigg |
| Wires and smal parts not made in fablab, like pulleys, timming belts, Tr screw and Tr nut, etc. |
Robotdigg, RS-Amidata, Farnell |
| Acrylic and vinyl |
Local supplier (DAGOL) and Fablab |
| Software (Autodesk Inventor, Corel Draw, Inkscape, Artcam, Arduino, Repetier with Slic3r) |
www.arduino.cc www.repetier.com |
How much will it cost?
I expect the total cost of parts will be about 600 Eur.
What parts and systems will be made?
I think I will make the major parts needed to this project, except the main controller (maybe I will use a sanguinololu), drivers and motors, of course. Some of small parts very difficult to make, like extruder tip or even heated bed that is cheap, I will acquire them also.
What processes will be used?
| parts/devices, etc. to be made |
What processes will be used? |
| Design (digital 3D modeling of parts and analysis of functional behavior of assembled sets) |
Autodesk Inventor (educational licence) |
| Structure and main holders to be made by aluminum |
Circular saw to cut aluminum profiles and lathe machining if it will be necessary |
| Fiber carbon plate |
CNC machining of carbon fiber sandwich, strips to cover cut sides, made by hand with epoxy resin and some carbon fiber blanket |
| ABS parts |
3D printing |
| Mechanical devices |
Artcam to post processing the 3D CAD models, and then, CNC machining of aluminum |
| Electronics, wiring, software, etc. |
Tutorials from fab academy and available all over the web |
| Covers (acrylic and vinyl) |
Corel Draw or Inkscape and then laser cutting |
| Parts to be drilled |
CNC machining or column drill machine |
| Parts to be carefully machined |
machining by hand |
what tasks need to be completed?
Global tasks:
Design the structure and all mechanical devices with a 3D CAD tool, test them in a digital way to ensure that they work together; Cut profiles and assemble the structure; Produce the post-processing files of 3D CAD models and Machine them; Assemble mechanical devices; Mount the devices on structure; Assemble parts for movements transmission and join them with the motors; test all the possible motions by hand and align everything needed for motion; Assemble main controller with motor stepper drivers and wiring; install software (repetier-host), manipulate firmware (with Arduino) to adapt it to the machine and upload it to controller (sanguinololu); Make a battery of tests and adjust all the settings (certainly it will be a very slow and patient process); Make an housing for the machine.
what questions need to be answered?
There are some questions that I have from the beginning:
What materials and arrangements make the best devices to work in this specific task? How to achieve good results of performance with low cost materials and available fabrication processes? How complicated is the software to work with it at daily time 3D printing?
What is the schedule?
Due to the amount of work I think I need various months to make something that works, so, because I have an employment also, maybe I need a Year, more or less, to complete this ambitious task.
How will it be evaluated?
One part will be the correct interaction between the mechanical, electronics, electrical and coding subsystems of the project. Finally, the most important is to achieve the main goal:
Get a strong, durable, reliable with easy maintenance requirements 3d printer to work intensively in any fablab environment. So, it must work during hours, reproduce the dimensions of digital model below a tolerance of 0,1 mm and make a lot of models keeping the repeatability.
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