Printing big

This is a pool drain ring ramp so the pool cleaner doesn't get stuck. Hole in the center is 8.25 inch ID with a 2 inch band.

Megarep printing video

Across town Dave is building his makerbot

A few tweaks and he will be primting Dave Thais for the conversation the bot is looking good.

An x axis shot to give it some scale

That's a half of a pool table used as a base.

Photo of the whole printer

That's a 24x24x16 inch print area

Mega rap still working out the bugs

Actual 3d object printed

First print a failure but it's a print

We can fix and tune it from here it's almost a printer.

Setting up steps to millimeters ratios

Using a digital gauge to determine distance of each move

3d printer stepper motor extruder

I am sure we will make this a more complete post some time in the future but for now here is a short version of the rabbit hole.

We built the Megarep to use stepper motor extruders. We figured by the time we were done building it eveyone would have it in their software.  This has not been the case, after working for a week trying to rework the the design to use a DC motor and finding that controlling the power was going to be an issue, it was time to start making the stepper motors work again. So here are the choices Comparison of RepRap software tool chains.

We began this project by using the makerbot boards with makerbot software path.  (makerbot firmware, replicatorg, SkeinForge compiler). This software is almost ready to support stepper motor extruder drivers, hopefully it will show up in version 2.1 of the makerbot firmware.

Our next choice was to upgrade the firmware to 5d and follow the reprap host software path. This also had it's trials.  More to come later but the bottom line is that tis was a very complex tool chain and just left us bewildered for a week.

Our current choice thanks to Matt at metrixcreatespace.com is starting to look promising. We are using 5d firmware with RepSnapper Driver software, and RepSnapper compilers. This tool chain has it's issues as well and is said to be a little unstable but we now have a system that can drive the stepper motor extruder for the Megarep. 


This has been a month long process to make the stepper motor extruder work. It would have taken even more time if we had not had the expert help from Matt. hopefully the next post you see will be the first 3d object from the Megarep. By the way it will be the traditional shot glass. :)

Extruding finally. Yeah hell yes!

Machined dual extruder head on the way

12 side circle print #1

It's alive

Started a test print using a pen at 6:42 Sunday night. The 40 oz z
motor wasn't enough to do the job. So new motors are on the way.

z axis drive belts finally arive

No picture I just wanted to add something new it seems like there hasn't been a post in a while.  It looks like we are only half day away from having x,y,z moving all the belts are here now. It's starting to be harder to find time to work on the project so we need another major milestone to get done to gain a little momentum again.

Getting close to having x y and z axis moving

Z motor tucked inside exoskin

Coming together

Z blocks in place

Better shot of x motors

Z motor with Axel

Just setting up to take measurements for a belt

Belts getting placed

X axis drives in place

X axis tensioners in place

Starting to assemble everthing again

We need to set the top of the z screws now that the base is set we can
start building up again.

Slate turned dark after a sealer was put on

Closeup of the jb weld bras inserts

Surfacing the jb welded screw inserts

Potting in the rest of the inserts

Z axis locks are here

Just a simple fastenal product

Z axis parts are done

We are about ready to do a minor assembly the robot should start
moving soon.

PLA holder is almost done

It's industrial strength but it's getting done. One more little thing
added to the ever growing list of completed steps.

High end design work

Highly technical work going on now

Top view z axis motor mount

Motor mounted to z axis

X axis drive motor mount

Rogers new toy

Just watching the master

A big picture with parts layout

X axis motor drive and gearing

It's not all built yet but you get the idea.

Z axis top rail

Z axis bushings

X axis idler parts

X axis drive layout parts

Vertical squares from piston liners

Everyone should use Detroit parts in there projects.

We need parts

Extruder feed wheel

Feed Wheel for Extruder

One more part. Yeah!!

Green PLA is here

Starting to be a megarep

Still needs a name but I like megarep it growing on me. We are just mocking up the top motor rail area. It will be the next part we start to build. It should let us finish seting the z axis.The days are long and the weekends are short but it's starting to feel like a real repstrap. A real big one that is.

Starting to mock up the top rail for the z motor and pullys

Close up of the z screw in place

Just posting from my phone

It's fast to post but it creates a lot of posts for the day