Intro
Neostruder is a toolkit that simplifies the integration of extruders with robotic arms for 3D printing by decoupling extruder control using two ESP32-based microcontrollers that stream OSC messages. This is inspired by comercial FDM printers decoupling the extruder from the rest of the control board. I designed a KUKA adapter that connects a 24V IO to a breakout board and an optocoupler, reducing the voltage to 5V, and a custom ESP32 PCB that monitors and controls the extruder’s functions with an OLED and KNOBS for manual adjustment. The components used include ESP32 microcontrollers, an optocoupler, a breakout board, custom PCBs, and custom 3D printed and laser cut mountings, costing around $200. The system includes a KUKA adapter, a custom control box, and custom mountings for DIN rails, fabricated through 3D printing, laser cutting, PCB design, and programming. This project addresses how to simplify extruder integration and control extrusion. The IO monitoring and control were successful, and future steps involve controlling extrusion speed. Evaluated through a functional proof of concept, Neostruder shows potential for modular, adaptable integration with various robotic arms, enhancing flexibility in 3D printing.
Neostruder: Simplifying Extruder Integration for Robotic Arms
What does it do?
Neostruder is a toolkit that simplifies the integration of extruders with robotic arms for 3D printing by decoupling extruder control using two ESP32-based microcontrollers that stream OSC messages.
Who’s done what beforehand?
This has been done in comercial grade 3D printers where the extruder control is independent from the control board.
What did you design?
I designed a KUKA adapter that connects a 24V IO to a breakout board and an optocoupler, reducing the voltage to 5V, and a custom ESP32 PCB that monitors and controls the extruder’s functions.
What materials and components were used?
- 3D printed mount for the extruder (3DP)
- PCB for the control box
- PCB for the KUKA adaptor
- Custom DIN rail mounts (Laser + 3DP)
- Display and knob mount (3DP)
- QTPY Esp32 (Adafruit compatible with XIAO)
Where did they come from?
Amazon, Sparkfun, Adafruit, Mouser
How much did they cost?
The total cost of the components was approximately $200.
What parts and systems were made?
The system includes a KUKA adapter for 24V IO, a custom control box, and custom mountings for DIN rails and extruder.
What processes were used?
The fabrication processes included 3D printing, laser cutting, PCB design, milling the box and programming of the ESP32 microcontrollers.
What questions were answered?
The project addressed how to simplify extruder integration with robotic arms and how to design a wireless protocol for this.
What worked? What didn’t?
The IO monitoring and control worked successfully. The next steps involve using analog voltage control to adjust the extrusion speed.
How was it evaluated?
The system was evaluated through a functional proof of concept that demonstrated the ability to start and stop the extruder to prevent oozing on a 3D printed part.
What are the implications?
Neostruder shows potential for a modular, adaptable system for integrating extruders with various robotic arms. Making this kit an easier way for a non technical user to integrate 3DP on a robotic arm.
BILL OF MATERIALS
- KUKA adapter for 24V IO to OSC data stream
- Custom control box that controls motor RPM, Fan Speed, monitors temperature.
- Custom ESP32 PCBs for the adapter and control box
- Custom 3DP parts for mounting fans and enclosing electronics.
| ITEM |
QTY |
LINK |
| MDPE |
1 |
LINK |
| ESP32 QTPY |
2 |
LINK |
| OLED i2c |
1 |
LINK |
| Rotary Encoder i2c |
1 |
LINK |
| KUKA breakout board |
1 |
LINK |
| Octocoupler |
1 |
LINK |
| Custom breakoutboard PCB |
1 |
LINK |
| Custom stepper PCB |
1 |
LINK |
| 3D print case |
1 |
LINK |