XLNC 2 - All in One Mill, 3D printer with custom Repetier Host CNC plugin and SolidWorks HSM post by crunchysann

Last crawled date: 3 years ago

Details of XLNC Rev 2.
If you are looking for the original XLNC - Rev 1, click here https://www.thingiverse.com/thing:1855391
Follow project updates on https://crunchysann.com/
Assembly videos in change-log below or click on any video to jump to the youtube playlist:
Basic final specs as pictured.
Machine footprint: 5'-5'-2.2'(L-W-H) (You can simply use shorter tubing to make a smaller, much more rigid machine)
Very large Build Volume when 3D printing: 32in-40in-12in(L-W-H) or 800mm X 800mm X 305mm
Very large Area when Milling: 32in-40in-Tool length (~4" +)
Motion: 1.25in ID (38.3mm)OD. Electrical conduit with user adjustable roller bearings
Use these SS tubes instead if you want to expand your machine cutting/ printing area past the specs above and for smoother finish on prints. Direct swap with no additional modifications. 1.5" OD 304 stainless steel rails. https://www.speedymetals.com/pc-4485-8276-1-12-od-x-065-wall-tube-304-stainless-steel-annealed.aspx
Materials supported: Cutting medium to soft grade aluminum and other softer materials
Intended usage CNC milling, Laser etching/cutting. 3D printing multiple objects simultaneously
Design Features:
Gantry on Z axis: The Gantry goes up and down on this design.
Steel re-enforced belts: Use 9 -10mm wide T5 - 5mm pitch (best) or GT3 spec belts and pulleys (MXL belts will fail very early ~ 10hrs use).
Stackable: Many of these machines can be stacked on top of one another
Support for toolset expansion: The gantry is made to support Wood routers, Dremels, heavy spindles, 3D printing filament Extruders (1 and up using mounting brackets), and is intended to support future robotic arm addition for hybrid 3D printing and finish milling operations.
Enclosure friendly: Since all movements are constrained within the machine's footprint, a full enclosure can be made for it.
Stiffer XY gantry: Future tests will be performed to get some actual numbers as to how accurately this particular design can cut hard materials. Since 3D printed parts are not well suited for FEA simulations, do not expect such testing to occur.
Adjustable Belt and Bearings: Belt tension is achieve using off the shelf products you can source at your local hardware store.
INSTRUCTIONS:
Download the following items:
"Rev 2.ZIP": This contains all mechanical STL and SolidWorks Part files for this machine. This is all you need in case you plan to use your own motion controllers (electronics) other than what is listed on this page.
"BOM.XLS": Bill of Materials (Mechanical BOM is posted with McMaster Part numbers where appropriate).
"XLNC PANEL BETA 1.ZIP": This is the XLNC plugin for Repetier Host (Extract and see installation instructions.docx file for install instructions)
"HSMWorks_3_Axis_Repetier_Rev5.js": Custom post-processor for SolidWorks HSMWorks (currently limited to 3 Axis X,Y,Z).
If using Vectric Aspire, download the Vectric Post for XLNC (Pending Upload).
Watch assembly instructions
Build your own enclosure or the one that will be uploaded
Update 1/14/2018: - Part 1 video added
https://www.youtube.com/watch?v=hzuDyIrcUQg&index=2&list=PL0kmIN05eLBDeOtj7yNt0PjGFq_5XDcCm
Update 1/15/2018: - Part 2 video added
https://www.youtube.com/watch?v=tO6ayekEFwg&list=PL0kmIN05eLBDeOtj7yNt0PjGFq_5XDcCm&index=1
-Assembling XY gantry
-Lastest STL files uploaded.
Update 1/16/2018: - Part 3 video added
https://www.youtube.com/watch?v=f6cAQV4VIGY&list=PL0kmIN05eLBDeOtj7yNt0PjGFq_5XDcCm&index=1
Update 1/16/2018: - Part 4 video added
https://www.youtube.com/watch?v=wPU8iiuRFs8&index=1&list=PL0kmIN05eLBDeOtj7yNt0PjGFq_5XDcCm
Update 1/16/2018: - Part 5 video added (updated video)
https://www.youtube.com/watch?v=5u6sC4Ff8es&t=25s&index=1&list=PL0kmIN05eLBDeOtj7yNt0PjGFq_5XDcCm
Update 1/17/2018:
New set of files uploaded (Includes fix for Z-axis roller couplers and new belt anchors)
Update 1/20/2018: - Part 6 video added
https://www.youtube.com/watch?v=ZNme7Kf5HWQ&list=PL0kmIN05eLBDeOtj7yNt0PjGFq_5XDcCm&index=1
Frame assembly completed successfully
Repetier CNC Plugin updated (GUI, DB backend)
Main frame design frozen. now routing belts
Update 1/28/2018: - Part 6B video added
Upgraded belt idler pulleys
Adjusted X axis belt anchor height to keep belts parallel to tubing
Rev 2. ZIP updated with new files
https://www.youtube.com/watch?v=ripbuyeqBGg
Update 1/30/2018: - Part 7 video added
Rev 2.ZIP updated: Added solidworks Part files
https://www.youtube.com/watch?v=X2mzTKvzbjw
Update 1/31/2018:
Rev 2.ZIP updated: Added Wire guide chain anchors for X / Y axis
Update 2/9/2018:
Rev 2.ZIP updated: Added Bed pipe holders
Update 2/23/2018:
Rev 2.ZIP updated: Added revised Bed pipe holders motors have been wired. adjusting repetier firmware
XLNC panel plugin status: Adjusting for execution on AMDx64 processors.
Update 3/11/2018:
Added 3D models for Diamond hot-end mount
Upgraded bed mounting brackets for stronger parts
Fixed panel compatibility with AMDx64 processors
Packaging XLNC Panel public Beta 1.
Parts Zip file updated.
Update 3/13/2018:
Snowed in sooooooo ¯_(ツ)_/¯
Shortened diamond hot-end spacer length
Updated REV2.ZIP file with latest models.
HSMWorks BETA post-processor added (3-Axis initially), generates Repetier and Marlin compatible G-code --Install HSMWorks (or free version) in solidworks and load this custom G-code (maybe video will follow once XLNC panel is released).
Update 3/17/2018:
Updated Diamond hotend mount to hold direct bowden style motors closer to extruder.
Assembly video: https://youtu.be/Vfb4KvHMQag
Update 4/1/2018:
Uploaded rudimentary mechanical BOM: QTY is for each piece (Not Packs). McMaster part numbers are added where appropriate, but feel free to source parts elsewhere.
Uploaded Solidworks source files and Mechanical assembly in MainFrame.Zip file.
Update 4/22/2018:
Uploaded XLNC Panel Beta 1 -- See File named XLNC PANEL BETA 1.ZIP
--Description: Built-in user interface for users of Repetier Host and Repetier/Marlin firmware to streamline usage of their printers as CNC mills or Laser cutters.
-- Currently Limited to 3 Axes but plans for 4 Axes may happen.
Installation instructions:
extract or unzip XLNC PANEL BETA 1.ZIP and read the installation instruction doc file
Update 4/25/2018:
Added basic wiring diagram explaining how to connect RADDS board to multiple GRBL shields, see file named "High level wiring diagram.pptx".
Update 5/9/2018:
printing calibration cubes with diamond hotend.
And a vase: https://youtu.be/9yQQ-uZJ8BM
Update 5/27/2018:
Calibration completed
Uploaded new Mixing extruder mount. Allows usage of Bstruder bowden style filament drive (https://www.thingiverse.com/thing:711401) with the diamond hotend. Instructions: Download zip file Rev2.zip..print the parts inside Rev2.zip/New Parts/Diamond Extruder Mount. Assembly is very simple (see instructions and screw dimensions on thing 711401)
Update 6/5/2018:
Well, the MXL belts broke (they weren't adequate either way) -- time for 9mm wide HTD steel fiber reinforced belts and pulleys (5mm pitch)
Pending update to XLNC Panel app to allow external gcode file execution
Started planning camera based tool offset alignment ad-don.
Update 6/25/2018
upgraded belts to 9mm wide 5mm pitch htd belts with 12 tooth pulleys
upgrading all steppers to nema 23 260oz for all around faster acceleration and cutting.
Potential upgrade to 1.5" OD 304 stainless steel rails for smoother finish on prints. https://www.speedymetals.com/pc-4485-8276-1-12-od-x-065-wall-tube-304-stainless-steel-annealed.aspx
pending upload of revised yx belt tensioner anchors
Sick of corner braces cracking during assembly...redesigning the 8 frame corner braces.
Update 6/30/2018
Testing new frame coupling design, see thing https://www.thingiverse.com/thing:2984817
The idea is to get a strong grip on electrical conduit without cracking the plastic pieces. --
This requires new Z axis motor mount for NEMA 17/23
Added bed leveling clamps for use on Glass bed when using as 3D printer.
Update 7/20/2018
re-enabling work in progress indicator due to upcoming upgrades to the z axis
apparently underestimated the thursts/forces applied to lower bearings and cheaping out on these leads to failed bearings on the z axis.
remodeling z axis frame supports so they can be attached to thing 2984817
searching for heavy duty drop in replacement lower thrust bearings
upgraded grbl shields to tb6560 boards for the time being (highly recommend 4 nema 23 motors for z axis and heavy duty drivers.)
Update 8/4/2018
Testing new Z axis mounts and drive nut mount
All printed parts can now be assembled without worrying about breaking plastic parts
All X,Y,Z Motor drivers upgraded to DM542T (RADDS board remains the motion controller)
Planing a new site to host projects and updates...Look forward to XLNC REV 3 (hopefully the last one :)
Update 2/20/2019

Planning project migration to its own website.

Project updates will be posted on this site from here on.
Follow my project here: https://crunchysann.com/BL/projects/