3D Printer CDR

Report
Meron Reda (Project Manager)
Brian Calinaya (System Engineer)
Lennon Nguyen (Power Train)
Moheb Youssef (3D Printing)
Peter Flores (Manufacturing Division Manager and Controls)
Changed the
Extruder Carriage to
account for melting
point limitations.
 Old PLA carriage had
melting point of
185° C.
 New ABS has melting
of 230° C.




Have the best print quality possible
Use parts that are ubiquitous
Reduce and minimize chance of backlash
◦ However some backlash may be present to prevent
jamming, allow for lubrication, etc.


We chose a smaller pulley to increase
resolution and to fit with the new belt
To fit the smaller pulley, we made the Y-Axis
motor attachment thinner



Design an air scrubber that eliminates all
toxic fumes and smells.
Must adhere to Sasha’s dimensions and
allows flexibility. We chose 27x24x20 inches.
The cost must not exceed $200.


Currently testing the
box for dead zones
and temperature
concerns.
Testing with ABS plastic
and adjusting the filter
tubing size accordingly


Retractable floor tray that the 3D printer sits
on in the box for easy access.
Add light sources in the box (Color LEDs)!

We have completed the Ramps Board section
of building the new 3D Printer and are
currently working on the exoskeleton.


We are currently at
the exoskeleton
stage of our build
process.
After, we will be
working on the
hotends and
x-bars.


A "subtractive" method for processing raw
material with a drill-like rotating cutter
through a set of computer-driven movements
of the cutting head.
Benefits: Fast, high accuracy, efficient

Design a CNC machine using a Dremel or
similar rotary type tool head and FoldaRap
structural base made of aluminum and
printed PLA plastic brackets.
LEVEL 1
 Complete CNC design
 Portable
 Uses printable parts
 Compact
◦ 335 x 348 x 318 mm LWH +21mm for handle
 Cost Effective
◦ Under $600
 Durable
◦ Aluminum structural support
LEVEL 2
 Counter resistance of different types of materials during
operation
 Dremel tool head is used for subtractive method
 Stepper motors to move axes in place of belts and pulleys;
less resistive



Unlike other CNC designs that use wood for the
structure, we chose to use the Foldarap as the
outer frame since it is made out of extruded
plastic, which we can print, and aluminum which is
sturdy and durable.
This design would be efficient because the
aluminum can hold up for years. Using stepper
motors to drive up the axes would be less resistive
and last longer. Printing the hinges and brackets
saves us money.
We based our CNC design on both the Prusa
Mendel and the Foldarap 3D printer


Assemble the
Foldarap Base as
seen in build
instructions manual
Can also find
instructional videos
online

X-Axis: Assemble as seen in the Foldarap Build Manual
except instead of 2 smooth rods, use 1 smooth rod and 1
threaded rod. Attach a stepper motor to one side with the
shaft facing horizontal. The stepper motor will be driving the
threaded rod.

Assemble Y-Axis, with two smooth rods and
one threaded rod in the middle to drive the
printed plate. A stepper motor will be
attached to the threaded rod.

Z-Axis: Assemble as seen in the Foldarap Build
Manual. Add stepper motors to the top of the zaxis screw drives.

We will be attaching a
Dremel in place of the
extruder carriage,
enclosed in a printed
holder, similar to the
one shown in the
picture.





Multi-speed from 5K
to 35K RPM
Quieter than other
models
Inexpensive at
around $80
Lightweight: 18.8 oz
Equipped with
multiple attachments
for the changing out
the tool head



Use ReplicatorG (http://replicat.org/) to
convert gcode or stl file
Use RAMPS board version 1.4, as in the Prusa
Mendel, to control the stepper motors that
are controlling the x, y, and z axes.
Use Marlin Firmware
Arduino Mega 2560


This board is the brain of our CNC machine and
serves as the main interface to the computer.
The Arduino board is programmed with a modified
Reprap Gcode interpreter and the 3 axes motion.
RAMPS Shield
RAMPS is a shield board that needs to be connected
to an Arduino MEGA 1280 or 2560 board.
 The Image shows a RAMPS board mounted on a
Arduino MEGA board with four Pololu stepper
motor controller boards installed

End Stop (Limit Switch)
 The switch and little
debounce circuit is, at
minimum mounted at
one end of each axis.
 Provide a home location
for the machine.
Qty.
Product Description
Product Number/SKU
RAMPS RepRap Arduino Mega Pololu Shield
1 electronics
1 AVR ARDUINO MEGA2560 REV 3
3 x Mechanical Endstop 3D printer, reprap, prusa,
1 mendel, makerbot
6 6mm Diameter x 300mm Length Smooth rod
2 6mm Diameter Threaded rod 1 meter
4 NEMA17 stepper motors
Printed Parts for structure
5 20x20 beam 6mm slot 1 meter
1 Dremel 4000
A000067
Source
http://www.ebay.com/it
m/RAMPS-RepRapArduino-Mega-PololuShield-electronicsassd-Pololus-kit-PCB/261105171806
http://www.mouser.co
m/ProductDetail/Arduin
o/A000067/?qs=gMoq
Xxk%2F%2F5apEOlL63o
O8Q%3D%3D&gclid=CL
uhwKu2yrMCFWlxQgodi
2UA7g
http://www.ebay.com/it
m/3-x-MechanicalEndstop-3D-printerreprap-prusa-mendelmakerbot/150922395345?pt=LH
_DefaultDomain_2&has
h=item2323acfed1
Salvaged from old
printers/scanners
http://www.screwfasten
ers.co.uk/threadedrods-0/stainless-steel0/threaded-rod-a2stainless-steel-din975-0/tige-filetee-m6inox-a2-din-975.html
Ebay
3D Printed
http://www.aluminiumprofile.co.uk/acatalog/
Aluminium_Profile_with
_6mm_Slot.html#aKJN_
20992_20888
Amazon
Unit Price
Total Price
$7.40
$7.40
$38.95
$38.95
$14.90
$14.90
$0.00
$0.00
$3.72
$10.00
$0.00
$7.44
$40.00
$0.00
$4.60
$79.00
$23.00
$79.00
$210.69

To get better efficiency and avoid calculating
the resistance of each printed material, look
into switching a Dremel tool head with a laser
cutter.
Qty.
Product
Number/SKU
Source
1 OPTIX 18 in. x 24 in. x .093 in. Acrylic Sheet
241610
Home Depot
$9.78
$9.78
2 OPTIX 11 in. x 14 in. x .093 in. Acrylic Sheet
241302
Home Depot
$4.24
$9.48
1/2 in. x 2 ft. x 4 ft. Medium Density
2 Fiberboard Handy Panel
279388
Home Depot
$8.97
$17.94
22078553622
Home Depot
$1.83
$1.83
201426
Home Depot
$11.48
$11.48
1 92 mm fan
N/A
Scrap parts
N/A
0
2 80 mm fan
N/A
Scrap parts
N/A
0
N/A
3D Printed
N/A
0
http://store.trinitylabs.com
LM-GT2PB /gt2-pulley-belt-set/
$30.00
$30.00
N/A
0
Product Description
Unit Price Total Price
Air Scrubber
1 Liquid Nails Projects 10 oz.
1 GE Carbon Replace Filter 2-Pack
Filter printed parts
Resolution Upgrade
1 GT2 Pulley & Belt Set
Extruder Carriage Upgrade
1 New Printed Extruder Carriage
N/A
3D Printed
$80.51

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