1 (edited by toobyaas 2014-12-19 12:08:25)

Topic: DIY Aluminium 3D-Printer, build 2 (page 4)

Hello everyone! So, I decided to register to this forum and create a project topic to tell everyone what I am building right now. I've been dreaming about own 3D-printer for a long time, so I decided to build one rather than buying complete printer. I searched electronics kit from ebay and found sintrons kit which includes Ramps 1.4, Mega 2560 R3, A4988 Stepper drivers, 5pcs Nema 17 motors, Heated bed and Extruder. I would give you a link, but I can't for some reason!

Package is now coming to me and plans is just about ready. I'am using aluminium for most of the parts and old three-axis Mazak cnc-lathe to produce them. So every part is planned so that it can be produced with it. It gives some constraints in parts size and hole location - holes need to be in the center of Z-axis.

I decided to make X- and Y-axis move bed and Z-axis moves only extruder. This is more complex structure than what we've seen for example in prusa i3. But I like challenges and if first version doesn't work I build a new. For the movement I am using metric thread rods, more closely M10 rod. This gives only 1,5mm movement per full circuit. It might be too slow or something but I try first with these! Linear guides are made from 12mm chromed bar and I think there is no problem.

I havent got any of my orders yet so I need to wait them before I can finish all plans.  I have ordered Sintrons kit, 12mm linear bearings and 1kg of black ABS filament. I've done couple parts already which are not depend of any parts that are in shipping to me.

There are four pics in attachment, because I can't make a link. But you can see them from there! There is render image from plans and three pics from finished parts.

Obiviously I forgot to tell lot of things so feel free to ask anything! I am newcomer to 3D-printers world and everything I do is new to me! Also, I'm from Finland so my english isn't too good, sorry about that.

Hopefully this interest you! smile And maybe I can get some advice from you!

Post's attachments

IMAG1299.jpg 287.32 kb, file has never been downloaded. 

IMAG1302.jpg
IMAG1302.jpg 408.15 kb, file has never been downloaded. 

Render.jpg 83.08 kb, file has never been downloaded. 

You don't have the permssions to download the attachments of this post.

2

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Looks like it is going to be a beefy  frame. 12 MM guide rods and bearings should be more than needed.


I decided to make X- and Y-axis move bed and Z-axis moves only extruder

based on what I am seeing. you do not have enough room for a full x move.  if you have an 8" bed you need 16 + inches of space between the  z axis rods .
IMHO move the x moves to the extruder.

this should be fine for the Z. if I was building a machine I would likly use acme thread instead of v thread.

I seriously consider building my own  but decided on a factory build to get my feet wet.
Tin

Soliddoodle 4 stock w glass bed------Folger Tech Prusa 2020 upgraded to and titan /aero extruder mirror bed
FT5 with titan/ E3D Aero------MP mini select w glass bed
MP Utimate maker pro-W bondtech extruder
Marlin/Repetier Host/ Slic3r and Cura

3

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Yeah, I was pretty impressed how steady the lower frame was when I put it together!  However it might be that I need to make straight plate where attach each corner. Because when evertyhing was put together, one corner was 1-2mm in air. However it doesn't need much pressure to put it down. Possibly that settles down when just accurately set everything in place.

Yes there is no room to use whole ped. Build area is going to be 150mm x 150mm so I'm not using whole capasity of bed. Actually I understood that just now big_smile Somehow I had visualization that the bed have 150x150 heated area but really it has 200x200. That's okay still.

Acme thread would be better of course, but first I try with normal metric rod because it is very much cheaper! If it doesn't work any good I'll try something else.

I understand you! That was the decision what I made also but decided to build my own smile Probably because I have NC-Lathe in use and materials costs nothing. It is fun to plan and make parts!

4 (edited by Tomek 2014-09-01 03:44:42)

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

I really like your work! Looks like great use of metal.

However, I am not a huge fan of the x-y bed.

One of the reasons why the prusa moves the bed seperately but not fully X-Y, is because that way axis that are planar in cartesian printing motion (i.e, only the x-y axis) are not all on the same mechanics. The idea being that errors don't propogate.

Whether that is really a valid design choice (for example, it is not a problem on any printer that chooses to do X-Y extruders), the bigger reason for avoiding X-Y beds is because of the weight of all that movement.

That said, perhaps it would work especially well for any application that has a very heavy extruder part, for one reason or another. (since you're not using a particularly moving extruder.)

5

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Thanks!

There are many reasons to use prusa-style movements rather than x-y bed, I know that. Prusa-style is tested in many variations and it works really good. It might be little stupid to do not use that kind of structure, but I want to test this x-y bed. Maybe problems are caused mainly by printed parts? I'm using machined aluminium parts which have better accuracy and they are stronger.

Weight is problem also. I have tried to design all the beds parts to be as light as possible! I'm also planning to build "billet extruder" from aluminium also, so that weight bit more than printed extruder. But that is somewhere in the future when printer is already working.

Let's see how it works big_smile Today I'm going to make more parts after my workaday. I'll add photos of them when they are ready. smile

6

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Very nice machining!

Looks like it will be a very strong unit...Good luck and keep us posted!

SD2 - Stock - Enclosure - Heated Bed - Glass Plate - Auto Fire Extinguisher
Ord Bot Hadron - RAMPS 1.4 - Bulldog XL - E3D v6 - 10" x 10" PCB Heated Build w/SSR - Glass Plate
Thanks for All of Your Help!

7

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Biggest problem with this design is weight (you already mentioned that). Since you are using all CNC metal parts, you have eliminated a lot of problems with other designs. What I see a big problem here is that you have so much weight making the X part of the bed move, you may have designed yourself right out of using the cheap stepper drivers used with most 3D printer electronics used today. They max out at 2 Amps (with extra cooling). Even if the higher torque stepper motors is enough to move the bed, momentum and mass will not allow you to have speed.

If you do switch the X axis onto the Z, you would eliminate most of that weight.

Chuck Bittner is a quadriplegic gamer who is petitioning the major console developers to include internal button remapping in all console games. You can help.
Sign Chuck Bittners petition

8 (edited by toobyaas 2014-09-01 17:55:59)

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

IronMan wrote:

Very nice machining!

Looks like it will be a very strong unit...Good luck and keep us posted!

Thanks! It is very strong smile Luck is what I need big_smile

Hazer wrote:

What I see a big problem here is that you have so much weight making the X part of the bed move, you may have designed yourself right out of using the cheap stepper drivers used with most 3D printer electronics used today. They max out at 2 Amps (with extra cooling). Even if the higher torque stepper motors is enough to move the bed, momentum and mass will not allow you to have speed.
If you do switch the X axis onto the Z, you would eliminate most of that weight.

Yep, this might be big problem. First I try to get the thing moving, then I try to make it accurate and finally try to make it fast. If I'm not happy with the speed, I need to make new structure! Maybe this is bad desing, but I'll give a try for it smile Do you know if there is better drivers somewhere in the internet?
One thing is good in my desing for sure! If I decide to change bed moving only on Y-axis, I can still use most of the main parts! Just need to make different lenght rods etc. smile


Today I made nuts for all axes, and their holders. Also made extuder bar holders. As you can see in one photo, I did measurements for nut. It gives around +-0,05mm backlash, so I decided to make "antibacklash nut" (photo is at next post). Basically need to put two nuts against each other, put spring between them, put little pressure by tightening second nut and lock it in position with screws. Maybe this will work?:D

In one photo you can also see the way I make most of parts. I think there is nothing to tell in another parts I made today smile Hopefully linear bearings reach me soon, so I could make bearing blocks. They are in pretty important role in the structure!

More photos in second post -->¨

By the way, there is one company nearby where I live that makes XY-bed printers and they seems to work very well! try to search "minifactory" in google or youtube. I can't still share links here yikes

Post's attachments

IMAG1324.jpg
IMAG1324.jpg 237.77 kb, 1 downloads since 2014-09-01 

IMAG1326.jpg
IMAG1326.jpg 318.05 kb, file has never been downloaded. 

IMAG1328.jpg
IMAG1328.jpg 390.98 kb, 2 downloads since 2014-09-01 

IMAG1330.jpg
IMAG1330.jpg 287.54 kb, 1 downloads since 2014-09-01 

IMAG1331.jpg
IMAG1331.jpg 338.44 kb, 1 downloads since 2014-09-01 

You don't have the permssions to download the attachments of this post.

9

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

More photos!

And thanks for replies! It's nice to see my work to interest people smile

Post's attachments

IMAG1325.jpg
IMAG1325.jpg 244.04 kb, 2 downloads since 2014-09-01 

IMAG1332.jpg
IMAG1332.jpg 342.98 kb, 1 downloads since 2014-09-01 

IMAG1333.jpg
IMAG1333.jpg 318.33 kb, 1 downloads since 2014-09-01 

You don't have the permssions to download the attachments of this post.

10

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Your mixture of alu and brass, and the delightful oversize aesthetic makes it look like you're building an early 20th century tower clock. I highly approve! smile

SD3. Mk2b + glass, heated enclosure, GT2 belts, direct drive y shaft, linear bearings, bowden-feed E3D v5 w/ 0.9° stepper
Smoothieboard via Octoprint on RPi

11

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Haha, nice to hear that you like! Sadly those are only brass parts that I'm making sad

12

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Next job:
http://www.my-time-machines.net/pouvill … tion24.htm
tongue

SD3. Mk2b + glass, heated enclosure, GT2 belts, direct drive y shaft, linear bearings, bowden-feed E3D v5 w/ 0.9° stepper
Smoothieboard via Octoprint on RPi

13

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Well, maybe I first try to get this ready big_smile

There is photo in attachment. It is assembled "antibacklash nut". It works pretty well, just need to fine tune length of springs.

Post's attachments

IMG_201409026938.jpg
IMG_201409026938.jpg 139.52 kb, 1 downloads since 2014-09-02 

You don't have the permssions to download the attachments of this post.

14

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

That's pretty. smile

SD3. Mk2b + glass, heated enclosure, GT2 belts, direct drive y shaft, linear bearings, bowden-feed E3D v5 w/ 0.9° stepper
Smoothieboard via Octoprint on RPi

15

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Beautiful!

Solidoodle 2 Pro - 3mm Glass Bed

16

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

SteamPunk 3D printer!

SD2 - Glass Bed, Fans on PCB and Y motor, Custom enclosure
Slicer - Simplify3D

17

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Thanks for everybody! Steampunk printer would be nice big_smile

Okay, today I made "Z-axis-raisers" which become attached to V-style part so it raises the attachmen point by 60mm. And also top part of the Z-axis. They have little ball bearing inside them which holds Z-screw in line. Made also threads to earlier parts (v-style, extruder bar attachment)

Postman brought me 10pcs LM12UU linear bearings, and 1kg of 1.75mm abs filament! smile Tomorrow I can make bearing blocks for them. Rest of printer parts might arrive tomorrow!

Post's attachments

IMAG1345.jpg
IMAG1345.jpg 304.99 kb, 1 downloads since 2014-09-02 

IMAG1347.jpg
IMAG1347.jpg 337.77 kb, 1 downloads since 2014-09-02 

IMAG1348.jpg
IMAG1348.jpg 274.95 kb, 1 downloads since 2014-09-02 

You don't have the permssions to download the attachments of this post.

18 (edited by toobyaas 2014-09-04 17:57:00)

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Hey all, lot of things is happened! I've been so busy with this, so I haven't found time to update progress sad Yesterday I made bearing bloks and parts arrived! I guess there is nothing special in them:
https://dl.dropboxusercontent.com/u/526 … 418922.jpg
https://dl.dropboxusercontent.com/u/526 … 431513.jpg

I got motors moving and assembled xy bed. Axles moves very fine and doesn't need too much force. Here is little video and photos about it. It succeed pretty well, I think!
https://db.tt/0vXfvRav
https://db.tt/9oRP2en4
https://db.tt/VGyLjYAv
https://db.tt/UfTdIDb4

But now I have a problem. I probably have microstepping on, and I really don't need it. So, I need to put like 3000 steps/mm in configuration to get right speed and It makes problems. Can I somehow put microstepping off? Thread rod itself works good! Put some volume to hear knocking..

19

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

that's awesome and thnks for sharing your experience.

20

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

I got a clicking sound and stalls like that when I first put my Hadron build into motion...adjusting the vrefs on the stepper drivers did the trick...

SD2 - Stock - Enclosure - Heated Bed - Glass Plate - Auto Fire Extinguisher
Ord Bot Hadron - RAMPS 1.4 - Bulldog XL - E3D v6 - 10" x 10" PCB Heated Build w/SSR - Glass Plate
Thanks for All of Your Help!

21

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

That is a work of art! Well-done toobyaas!

Wow.

Two SD3s - One with Sang, One with Printrboard, Fans on control boards!!! Do this!!!, Dual Glass Beds, Blacklight "EZ Bake Oven" - Improves Ambient Temp, Sketchup, Repetier, Slic3r. Graphic Designer & Makeshift Engineer. Drinks Lots and Lots and Lots of Rum.

22

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

All the images and videos are blocked at work! I'll have to wait until I get home to see all this marvelous work! sad
Really impressed at your turnaround speed, toobyas... I normally take years to bolt one thing onto another!

SD3. Mk2b + glass, heated enclosure, GT2 belts, direct drive y shaft, linear bearings, bowden-feed E3D v5 w/ 0.9° stepper
Smoothieboard via Octoprint on RPi

23

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Thanks to all! It's so nice to see people liking my work smile I always do work like a crazy when I exited of something big_smile For now I've used ~15h for planning and ~29h for making parts. In this week I have done every day about five hours my parts after eight hour shift big_smile

IronMan, thanks for the tip! I will try that if following doesn't help.
Okay, I'll answer to myself! There should be three jumpers under every stepper driver. By taking all three off, I should reach full stepping! This is quite necessary, because when I put needed steps/mm, it feels like driver goes crazy. Motor just don't move like it should. Anyway microstepping is unecessary because  1/16 step gives theoretically 0,0003125mm movement..

Can't wait to get home and test these things! By the way, do anyone know what is the speed  of movement when moving axis from LCD controller?

24

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Subscribe! Awesome project!

25 (edited by toobyaas 2014-09-05 16:05:14)

Re: DIY Aluminium 3D-Printer, build 2 (page 4)

Thank you!

I have got forward with problem. I can get motor spinning in right steps/mm. In videos I'm using 1/2 step mode. Problem is that when the motor tries to spin fast, suddenly it doesn't spin..? I've tried to adjust vrefs, but no help. Better in second video because I put more accerlation distance!


What would cause this kind of behavior? Hopefully someone knows! Thanks smile

Edit: It works pretty good with 15mm/sec speed. However that is pretty low speed. It's 600rpm, maybe I should give up on threaded rod..
Then I met this http://www.thingiverse.com/make:42552
https://www.youtube.com/watch?v=uzSgV8E … nqS7hS4TZg

Could I do it with 3 axis lathe.. hmm..