3D Printer 051 - Large - 500x320x200mm Build Volume

Last crawled date: 1 year, 11 months ago

Functional real-world 3D printer build lacking the majority of the junk/popular linear motion, bearings, or 3D printed components found on inexpensive DIY or commercial machines. Easy assembly and maintenance with adult hand size tools and torque wrench.

Update: 6 +/- months of near-daily light use has required no repairs or adjustments other than the usual efforts necessary to keep an extruder functioning. A "glaze" appeared on the rail bearing surfaces after a few days of use (just like that seen on a CNC plasma table with similar rails and same bearings that has also not required adjustments).

Oversize build area allows output of many small objects at once. Open front case design allows (the rather large) machine to pass through a 24" doorway into purchaser's work room. Pictured wiring embedded in a slot with hot glue was a really bad idea - removal is nearly impossible without damaging the wiring and nothing can be added later. Embed tubing to use as conduit instead...

RM2-2RS bearings in routed V grooves on phenolic resin rails (lab countertop scraps) and NSK 25mm linear rails/trucks. 84oz. NEMA 17's for X, Y, and 269oz. NEMA 23 for Z. 2GT pulleys, Gates 6mm 2GT belting (ordered), 1/2in. ACME threaded rod, Delrin anti-backlash nut, Openbuilds smooth idler pulleys with 688 bearings (not the 5mm ID. bearings in their "kit"). 12mm inductive proximity sensors.

Common metric and imperial fasteners, pocket hole screws, staples, and TiteBond Supreme glue. 1in. and 3/4in. Columbia Purebond birch and oak plywood case. PPG black powder coat media. CNC routed wood, resin, and plasma cut steel parts with easy bends. EMT conduit and vinyl tubing (outer spiral spring support back-ordered) for wire management.

Clearances were added in CAM or manually and are not present unless noted in individual part names. Pocket hole screw detail not shown. Metal to metal component contacts without fasteners are welds. However a bed is attached it **must** prevent the support arms from twisting. The 3/8in. fasteners were torqued (dry) to 24 ft. lbs. and 5/16in. to 12 ft. lbs. where appropriate.

Currently using Marlin 2.0 on SKR v1.1 controller/LCD12864 with DRV8825 step drivers for small motors and a generic external Toshiba TB6600 based driver for Z, all at 32X microstepping (which pushes limits of the controller at higher speeds). External MOSFET driver for extruder heater (and a second spare for an upgrade or expansion).

External TF to SD Card adapter (Amazon) in a (purely cosmetic) bracket and lightly secured with hot-snot from behind. Connects directly to controller TF slot to eliminate issues/inconvenience/cable problems with LCD12864's fragile/error-prone/POS onboard SD Card reader.

Level converters for sensors (which function best at 12-24V DC) are common LM7805 voltage regulators (use a brand name IC for fast turn-on, lower drop out, and low noise w/o needing external caps) in TO220 packages mounted to controller bracket as a (unneeded) heat sink and output 5V for controller's inputs. 12V DC 18A Dell branded switching power supply.

Generic MK8 Extruder was disassembled and the anodized aluminum parts were soaked in lye for a few minutes to remove original dog-vomit-orange (which looks gold in online ads).

Metal parts cut on this plasma table:
https://grabcad.com/library/inexpensive-budget-cnc-plasma-table-1

Name Brand Stepper Motors:
https://www.ebay.com/sch/tony34306/m.html?_nkw=&_armrs=1&_ipg=&_from=

Delrin Smooth Idler Pulleys (obtain 688 or F688 bearings elsewhere):
https://openbuildspartstore.com/smooth-idler-pulley-wheel/

SKR v1.1 Controller:
https://github.com/bigtreetech/BIGTREETECH-SKR-V1.1

External MOSFET Modules:
https://www.amazon.com/gp/product/B07X8XPDR4

External SD Card Reader:
https://www.amazon.com/LANMU-Extension-Flexible-Monoprice-Raspberry/dp/B01D9JIUU0

Generic MK8 Extruder:
https://www.amazon.com/gp/product/B078NR2YHZ

ST LM7805 Positive 5 Volt Regulator TO220:
https://www.ebay.com/itm/L7805CV-L7805-7805-Positive-Voltage-Regulator-IC-5V-1A-TO-220-5-100pcs-USA/223105274174

Similar Dell 12V Switching Power Supply:
https://www.ebay.com/itm/Lot-of-5-Dell-DA-2-Series-ADP-220AB-12V-18A-AC-DC-Adapter-Power-Supply-OEM/133433576813

RM2-2RS Dual Row Stainless Steel Bearings:
https://www.ebay.com/sch/i.html?_from=R40&_nkw=rm2-2rs+bearing&_sacat=0

Delrin Anti-Backlash Nut For 1/2" ACME (A similar DumpsterCNC part would be better)
http://www.ebaystores.com/imsrv