FlashForge Dreamer Thermostat Mount by BaronWilliams

Last crawled date: 3 years ago

FlashForge Dreamer Thermostat Mount
This mount is for adding a custom thermostat to your FlashForge Dreamer for controlling the internal build temperature. I created this project because my FlashForge Dreamer is the version without a thermostat controlled interior temperature, and no fans on the back, so it could overheat when printing with ABS with the lid is on. To solve overheating issues and to improve printing of overhangs I added a custom thermostat to my Dreamer that's used to automatically turn on 4 extra cooling fans I installed (2 on the back and 2 on the sides). I also have my fans connected to a switch so that I can manually turn them on if needed (the switch is not covered in this article). Some versions of the Dreamer already have fans on the back which are thermostatically controlled. If your Dreamer is that version, then this will probably be of little benefit to you.
The mount consists of 4 pieces.
ThermostatMagnetPlate - this mounts on the side of the Dreamer via screws. It's designed to be mounted once and never removed. Magnets are glued to it. These hold attachments in place without the needs for screws. In this case the attachment is the ThermostatMagnetMount.
ThermostatMagnetMount - this attaches to the thermostat via M3 nuts and bolts. It's not connected to the Dreamer with nuts or bolts. It's connected via magnets. This allows the part to be easy removed, repaired, etc., without having to deal with tools. The area where this install is difficult to get access to with tools. That's the reason I used magnets instead bolts to attach it to the magnetic ThermostatMagnetPlate.
ThermostatMagnetCover - used to hold magnets inside the ThermostatMagnetMount.
ThermostatSensorHolder - used to hold the thermostat's temperature sensor. The sensor is simply held in place by gravity. This sensor holder puts the senor near the left front top of the Dreamer, and good location for reading internal temperature without interfering with the print head.
Why Use Magnets?
Why use magnets? Why not screws or bolts for everything? The mounting location doesn't allow for the use of bolts because I have no access to the back side between the mounting location and the sidewall of the Dreamer, unless I wanted to drill holes in the side wall, which is not something I wanted to do. The mounting location chosen for the thermostat already contained 4 screw holes which are not used in my FlashForge Dreamer. So I made use of them. By using these existing screw holes, I didn't need to drill any additional holes in the Dreamer's body. However, this location is quite difficult to get access to. If I needed to remove the thermostat for some reason, unscrewing it would be difficult, and would eventually strip the plastic screw holes.
I wanted a convenient way to install and remove the thermostat, but I didn't want to wear out the screw holes on the Dreamer. I could have opted to make a plate that screws into this location that has it's own screw holes for attaching the thermostat to, but that would not solve the problem of the plastic screw holes eventually stripping. It just moves the stripping to a different location. Since I couldn't easily use bolts in this location, I needed another solution.
I decided to design the ThermostatMagnetPlate to be a permanent part of my printer. I never plan to remove it because I don't want to strip the screw holes on the Dreamer. Instead of mounting the thermostat using screws, onto this plate, I decided to use magnets. Magnets will not cause wear on the Dreamer's body.
With this design, using the magnets, I can remove the thermostat dozens of times without needing any tools and I don't need to worry about ever stripping the screw holes. So while the magnets are an extra step to do initially, they are cheap, and they make maintenance work a breeze. The neodymium magnets are extremely strong. They hold the thermostat securely in place. You have to seriously pull the thermostat piece with force before it comes loose from the magnet mount. There's no worry of it coming off on it's own.
Why use neodymium magnets and not other magnets? Neodymium magnets are super strong, they are not the typical magnet most people are used to. They have considerable pulling force. I wouldn't consider using regular magnets for this project. With the neodymium magnets, the thermostat almost feels like its bolted down. It's that strong. You will be surprised how strong they hold the thermostat in place. If the typical ceramic or ferrite magnets were used, it would be possible to shake the thermostat lose with a strong bump to the side of the printer. That's not possible with the neodymium magnets. Unless you forcefully pull off the thermostat, it's staying put!
See Also
For side fan mounts see here: http://www.thingiverse.com/thing:667612
For back fan short filament guide tubing clips see here:
http://www.thingiverse.com/thing:667620
Thermostat Used
The thermostat I used is a 12v DC thermostat. It can be set to turn on or off at any particular temperature I need between -50-110 °C. I have mine set to turn on fans at 50 C currently. (I have also wired up a switch to bypass the thermostat, but that's not part of this project).
The exact thermostat I used is a cheap generic thermostat found at these locations:
http://www.amazon.com/gp/product/B00GWFK7FA
http://www.amazon.com/RioRand-Thermostat-Temperature-Controller-Waterproof/dp/B00KCCX0EE
There is unfortunately no company name on it. The model number is W1209. It has been working well for many months. It's got quite a bit of settings to tweak using the 3 front buttons. Making temperature changes requires just touch 2 buttons. It's very easy to use.
Step Down Converter Used
For this project I used a SMAKN DC/DC 24V to 12V/6A Step Down Converter. It can be found here:
http://www.amazon.com/gp/product/B00H3YN9H2
Wires Used
All wires were 18 gauge.
Nuts And Bolts Used
The FlashForge Dreamer uses standard M3 nuts and bolts. I used two M3 nuts for attaching the sensor, and step down converter.
For the thermostat mount, I used four #3 x 5/8" screws.
Fans Used
Fans should be 80x80x15mm fans. I used 12 V DC fans, but 24 V DC fans can also be used. The fans altogether should not use more than 1.4 amps.
Magnets Used
Neodymium magnets with a diameter of 1/4" with a thickness of 1/16"
Notes
THERE MAY BE SOME MISSING DETAILS IN THE INSTRUCTIONS. I WILL GO OVER THIS AGAIN LATER WHEN I HAVE TIME TO ENSURE THAT EVERYTHING IS CORRECT.
IF YOU NEED ANY HELP OR NOTICED ANY INSTRUCTIONS MISSING PLEASE LEAVE A COMMENT.
THANKS.