1 Topic by elmoret

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Topic: Filastruder Documentation and CAD/STL files

We'll keep the documentation and CAD/STL files posted here.

____________________________________________________________________________________
Revision 2.1 of the instructions and CAD/STL files (FOR SERIAL NUMBERS 2729-2823)

Revision 2.1a of the instructions and CAD/STL files (FOR SERIAL NUMBERS 2823-2962)

Revision 2.1b of the instructions and CAD/STL files (FOR SERIAL NUMBERS 2963-3008)

Revision 2.1c of the instructions and CAD/STL files (FOR SERIAL NUMBERS 3009-3126)

Revision 2.1d of the instructions and CAD/STL files (FOR SERIAL NUMBERS 3127-3842)

Revision 2.1e of the instructions and CAD/STL files (FOR SERIAL NUMBERS 3843-present
____________________________________________________________________________________

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

2 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

Filastruder Kit revisions:

All revisions beyond beta testing will have serial numbers, and their specific variations posted here.

Alpha:
Never left my workbench
Held together with cardboard and painter's tape
Worked!

Beta v1:
Used 4-flange design
Printable hopper v1

Beta v2:
Printable hopper v2
Deleted 2 of the flanges, replaced with longer heater barrel
Added nylon spacers to fix thrust bearing misalignment issue
Upgraded coupling to 9mm hex socket
Late v2 models got upgraded motor, similar torque and RPM but brings and internals, quieter

Kickstarter: (Serial numbers 1-133)
Heater, motor, fan, and PID controller run on 12v DC through switching mode brick
Other "vitamins" unchanged from the Beta v2 version at this time
Printable parts updated (now v5 hopper, v2 electronics, same v2 hopper funnel)
Assembly instructions updated
Fully assembled version released

Kickstarter v1.1: (Serial numbers 134-468)
Changed feedscrew, deleted threaded bushing, stronger thrust bearing, changed shaft coupling to 7/16".
Changed to more easily swappable hotends, flange mounts on the front of the support
Added angle brackets to make assembly easier
Started shipping Sestos controllers
Assembly instructions updated

Release v1.2: (Serial numbers 469-534)
Upgraded motor, roughly doubles extrusion speed
Assembly instructions updated

Release v1.3: (Serial numbers 535-828)
Changed feedscrew, performance unchanged
Changed thrust bearing and hex coupling to match new feedscrew
Changed washer-style coupling key to stainless steel dowel pin
Changed to wooden thrust plate instead of flange
Changed to stainless steel pipe coupling, changed heater band diameter from 1.1" to 1.0" to match
Changed to metal angle brackets
Assembly instructions updated

Release v1.4: (Serial numbers 829-1016)
Changed feedscrew, performance unchanged
Changed hex coupling to match new feedscrew
Changed back to bushing+flange thrust plate
Change to clamp-style shaft collar
Barrel diameter a few hundred microns smaller
Assembly instructions updated

Release v1.5: (Serial numbers 1017-1597)
Gearmotor updated to square shaft

Release v1.6: (Serial numbers 1598-1980)
Gearmotor updated to "beta motor"
Stall protection added to limit gear motor output torque

Release v2.0: (Serial numbers 1981-2728)
Gearmotor updated to GF45 series
Changed to all metal chassis
Thrust bearing spacer changed to gray washer
Fully insulated barrel
2-piece threaded hopper
Melt filter nozzle by default
Stall protection now has current and voltage display
Note: From S/N 2675 onward, feedscrew was changed somewhat resulting in improved (tighter) fit. Also heater wires were lengthened so splicing is no longer required.

Release v2.1: (Serial numbers 2729-present)
Changed to acrylic enclosure instead of lasercut MDF
Removed nylon mesh covering insulation
Slightly larger auger, resulting in less space between the inside of the barrel and the outer edge of the auger
Fan and heater not have long wires that do not need extending
The last few dozen of the v2.0 had the slightly larger auger and longer fan/heater wires.
v2.1e has changes to wiring, for easy of use/assembly


Filastruder licences:
All Filastruder files and design are licensed under CC-BY-NC.

Old revisions of documentaion:

____________________________________________________________________________________

Revision 2.0 of the instructions and CAD/STL files (FOR SERIAL NUMBERS 1981-2728)

Revision 1.6 of the instructions and CAD/STL files (FOR SERIAL NUMBERS 1598-1980)

Revision 1.5 of the instructions and CAD/STL files (FOR SERIAL NUMBERS 1017-1598)

Revision 1.4 of the instructions and CAD/STL files (FOR SERIAL NUMBERS 829-1016)

Revision 1.3 of the instructions and CAD/STL files (FOR SERIAL NUMBERS 535-828)

Revision 1.2 of the instructions and CAD/STL files (FOR SERIAL NUMBERS 469-534)

Revision 1.1 of the instructions and CAD/STL files (FOR KICKSTARTER BACKERS)

Revision 1.0 of the instructions and CAD/STL files (FOR KICKSTARTER BACKERS)

Assembly video, v1.0 Kickstarter kits only
____________________________________________________________________________________

Revision 0.7 of the instructions and CAD/STL files (FOR BETA TESTERS ONLY)
____________________________________________________________________________________

Revision 1.1 of the operation manual for the Fully Assembled Filastruder (Printed guide bar parts, Serial # FA1-FA178 except FA140)

Revision 1.2 of the operation manual for the Fully Assembled Filastruder (Lasercut guide bar parts, Serial # FA140, FA179-present)

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

3 Reply by drandolph

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Re: Filastruder Documentation and CAD/STL files

So I made a new version of the hopper funnel. I didn't like how it fitted to the hopper and how thin the whole structure was. This version has thicker walls to match the strength of the hopper. It also has a recess and lip to hold the hopper firmly and give you a solid glue surface. I also curved the inside and top edge to keep the pellets flowing downward with gravity. You can print it with no support structure and remove the one I put in when your done. All of the external measurements are still the same.

This forum won't let me post links but go over to thingiverse and look for item 82611.

4 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

Thanks! Link is here:

http://www.thingiverse.com/thing:82611

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

5 Reply by samr7

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Re: Filastruder Documentation and CAD/STL files

Hi Tim,

When I loaded the Kickstarter Hopper v5 STL into Slic3r, it generated G-code to print it upside-down.  Any chance of saving an STL that is flipped?

Thanks, and thank you for creating this wonderful machine.

-Sam

6 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

samr7 wrote:

Hi Tim,

When I loaded the Kickstarter Hopper v5 STL into Slic3r, it generated G-code to print it upside-down.  Any chance of saving an STL that is flipped?

Thanks, and thank you for creating this wonderful machine.

-Sam

Whoopsies. I'll fix it.

Also, it's a good idea not to download anything until you kit arrives, in case there are improvements made along the way!

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

7 Reply by jesse (edited by jesse 2013-05-15 23:05:44)

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Re: Filastruder Documentation and CAD/STL files

Do you recommend printing the 3d models with PLA or ABS?

Is there a way of getting the wooden case in the Kickstarter video?

8 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

jesse wrote:

Do you recommend printing the 3d models with PLA or ABS?

Is there a way of getting the wooden case in the Kickstarter video?

I've always printed them in ABS. The only part that might not work well in PLA is the hopper. The steel barrel is about 65C at the hopper while extruding ABS.

OS Printing plans on releasing the wooden case files at the end of May - I'm a little ahead of schedule shipping. smile

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

9 Reply by Nimikin

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Re: Filastruder Documentation and CAD/STL files

If anyone missed it, Tim has uploaded the build video http://www.youtube.com/watch?v=4ek03ugI … e=youtu.be

10 Reply by jesse (edited by jesse 2013-05-18 14:58:37)

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Re: Filastruder Documentation and CAD/STL files

Thanks Tim.

What type/percentage of infill should the 3d parts be printed at?

11 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

I usually print at 80% line, but anything over 50% is probably fine.

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

12 Reply by jesse (edited by jesse 2013-05-19 12:24:01)

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Re: Filastruder Documentation and CAD/STL files

Is it important that the wood platform be exactly 22 inches long?

The piece of wood I bought is 1x6x24 inches at (Poplar, Lowes, $5).

13 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

That should be fine, though they'll cut it for free. smile

You might want to place the motor mount an inch or two from the edge of the board, instead of on the edge like the video.

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

14 Reply by drandolph

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Re: Filastruder Documentation and CAD/STL files

I just finished a laser cut case for my kit.
For those who have access to a laser cutter and got the kit here you go.
http://www.thingiverse.com/thing:92815

#27

15 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

Seriously impressive! Thanks!

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

16 Reply by nachokaos

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Re: Filastruder Documentation and CAD/STL files

what about how to fix the thermocoupler in Ks messages,are you going to upgrade the instructions iam really lost to understand how to fix it.

great job drandolph.

17 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

nachokaos wrote:

what about how to fix the thermocoupler in Ks messages,are you going to upgrade the instructions iam really lost to understand how to fix it.

great job drandolph.


How to fix it? You mean attach it?

There should be a hole in the side of the nozzle, just slide the probe in and tape it in place with Kapton tape.

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

18 Reply by nachokaos

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Re: Filastruder Documentation and CAD/STL files

yes attach it !! sorry i been translate the instructions and some things and technical expressions dont make so much sense after pass true the google translator.....
thank you Tim.

19 Reply by jesse

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Re: Filastruder Documentation and CAD/STL files

Is it more important to get the pipe as tight as possible or to get the cut out facing straight up?

20 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

Get it as tight as possible without the cutout being turned more than 45 degrees from vertical. If it gets turned more, pull the 4 bolts out and rotate the assembly 90 degrees.

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

21 Reply by jesse (edited by jesse 2013-05-25 15:14:17)

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Re: Filastruder Documentation and CAD/STL files

Does the thermocouple need to be insulated from the brass nozzle?

Would you recommend covering the fiberglass insulation with aluminum foil to contain the heat?

22 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

Nope, definitely don't insulate it or it won't get a accurate temperature! The teflon insulation is good to 250C or so.

You can cover the insulation with foil if you want, but since foil is a great conductor it won't do much to contain heat...

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

23 Reply by jesse

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Re: Filastruder Documentation and CAD/STL files

Thanks, Tim.

Do you have any instructions for using/tuning the temperature controller?

24 Reply by elmoret

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Re: Filastruder Documentation and CAD/STL files

jesse wrote:

Thanks, Tim.

Do you have any instructions for using/tuning the temperature controller?

You might want to auto tune it - instructions are in the "Lessons learned so far" section. There should have been instructions in the box for the controller also.

Filastruder - the robust, inexpensive filament extruder
E3Dv6 All Metal Hotend - the premier 3D printing hotend

25 Reply by jesse (edited by jesse 2013-05-25 21:15:21)

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Re: Filastruder Documentation and CAD/STL files

I was able to get it working.

PV = Present value
SV = Set value
hysteresis = dependence on a system not only on its current environment but also it's past environment
PID = Proportional, Integral, Derivative
TC = thermocouple

The alarm value needs to be changed from 100 to 180 in order to get SV to reach PV 180.

The temperature inside the filament hole was measured to be around 188 degrees C using a digital thermometer with the same type of thermocouple.  That was after setting the temperature to 180 degrees C using the PID.  I guess I'll fill in the thermocouple hole with RTV silicone ($3 on harbor freight) to prevent air from getting in.

Which direction should the shaft be rotating with the perspective of motor on the right side?