thinkaweek

Clean up complete for now

2011-01-23T12:02:00.000-08:00

Control box mounted, pid extruder temp control box mounted, wires restrung rehooked up. Heat lamps are on an outlet strip for now. Heated bed is on the arduino pid and inside the control box. The new tempered glass is here ( the old space invaders glass had to many fractured and broke when we started cycling the heat.

Moved the extruder pid

2011-01-23T11:56:00.000-08:00

It was time for some clean up work so we in taped the extruder pid and put on the side in an old project box we had. The switch might be for a set of heat lamps to soon to tell

Craigslisted out old parts ( sold)

2011-01-23T11:52:00.000-08:00

Since we went to the ramps system we decided to sell our inventory of makerbot boards. We were surprised at the collection once we got it all together.

Had a driver board meltdown

2011-01-23T11:50:00.001-08:00

We lost a capacitor on one of the driver boards It probably still works it's just a little burnt. We ordered another couple of boards. Multimachine you guys rock great service.

New multimachine ramps installed

2011-01-23T11:46:00.000-08:00

We have always had some communication issues in this design with the old generation makerbot boards. We decided it was time to try the ramps package from multimachine. Our results were impressive almost all of our issues with communication errors have gone away.

Adding a heated bed and other things

2011-01-23T11:40:00.000-08:00

Time to start getting this machine to a highly reliable state. Lots of improvements on the way.

First step add a heated bed. We used an arduino as a pid controller and this hotplate element as the heater. We covered it with an aluminum plate and set it under our glass. The photo shows the underside view.

Printing big

2010-09-12T18:43:00.000-07:00

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

2010-07-25T22:54:00.000-07:00

Across town Dave is building his makerbot

2010-07-25T22:51:00.000-07:00

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

2010-07-25T22:48:00.000-07:00

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

Photo of the whole printer

2010-07-25T22:47:00.000-07:00

That's a 24x24x16 inch print area

Mega rap still working out the bugs

2010-07-25T22:44:00.000-07:00

Actual 3d object printed

2010-07-12T14:32:00.000-07:00

First print a failure but it's a print

2010-06-27T21:37:00.000-07:00

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

Setting up steps to millimeters ratios

2010-06-27T21:35:00.000-07:00

Using a digital gauge to determine distance of each move

3d printer stepper motor extruder

2010-05-12T07:11:00.000-07:00

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!

2010-04-18T01:46:00.001-07:00

Machined dual extruder head on the way

2010-04-11T19:32:00.001-07:00

12 side circle print #1

2010-04-06T07:41:00.001-07:00

It's alive

2010-04-06T07:40:00.001-07:00

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

2010-03-29T22:12:00.000-07:00

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

2010-03-14T23:27:00.001-07:00

Z motor tucked inside exoskin

2010-03-14T23:23:00.001-07:00

Coming together

2010-03-14T23:20:00.000-07:00

Z blocks in place

2010-03-14T23:14:00.000-07:00

Better shot of x motors

2010-03-14T22:43:00.001-07:00

Z motor with Axel

2010-03-14T22:41:00.000-07:00

Just setting up to take measurements for a belt

2010-03-14T22:40:00.001-07:00

Belts getting placed

2010-03-14T22:04:00.001-07:00

X axis drives in place

2010-03-14T22:03:00.001-07:00

X axis tensioners in place

2010-03-14T22:00:00.000-07:00

Starting to assemble everthing again

2010-03-14T21:58:00.001-07:00

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

2010-03-14T21:56:00.001-07:00

Closeup of the jb weld bras inserts

2010-03-14T21:54:00.000-07:00

Surfacing the jb welded screw inserts

2010-03-14T21:53:00.000-07:00

Potting in the rest of the inserts

2010-03-14T21:52:00.000-07:00

Z axis locks are here

2010-03-03T08:30:00.001-08:00

Just a simple fastenal product

Z axis parts are done

2010-02-28T18:03:00.001-08:00

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

PLA holder is almost done

2010-02-28T18:01:00.001-08:00

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

2010-02-23T22:24:00.000-08:00

Highly technical work going on now

Top view z axis motor mount

2010-02-23T22:23:00.000-08:00

Motor mounted to z axis

2010-02-23T22:22:00.000-08:00

X axis drive motor mount

2010-02-23T22:21:00.000-08:00

Rogers new toy

2010-02-14T16:54:00.000-08:00

Just watching the master

A big picture with parts layout

2010-02-14T12:57:00.001-08:00

X axis motor drive and gearing

2010-02-14T12:50:00.001-08:00

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

Z axis top rail

2010-02-14T12:48:00.001-08:00

Z axis bushings

2010-02-14T12:47:00.001-08:00

X axis idler parts

2010-02-14T12:45:00.000-08:00

X axis drive layout parts

2010-02-14T12:44:00.000-08:00

Vertical squares from piston liners

2010-02-14T12:02:00.000-08:00

Everyone should use Detroit parts in there projects.

We need parts

2010-02-12T21:01:00.001-08:00

Extruder feed wheel

2010-02-12T09:15:00.001-08:00

Feed Wheel for Extruder

2010-02-09T07:59:00.000-08:00

One more part. Yeah!!

Green PLA is here

2010-02-06T11:25:00.001-08:00

Starting to be a megarep

2010-01-31T20:52:00.000-08:00

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

2010-01-31T20:44:00.000-08:00

Close up of the z screw in place

2010-01-31T20:41:00.000-08:00

Just posting from my phone

2010-01-31T20:40:00.000-08:00

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

Installing the z acme screws

2010-01-31T20:38:00.001-08:00

Now that we have the y axis face plate on we can finally put the z
scwers into place.

Y axis extruder plate and face plate

2010-01-31T20:35:00.001-08:00

Extruded face for the y axis

2010-01-31T20:34:00.001-08:00

Nothing like repurposing an old door seal plate.

Just a few more hours on the mill is all

2010-01-31T20:31:00.000-08:00

Thanks Roger and Marcia we appreciate the use of your shop and the hospitality suite.

Angle backing for belt lock

2010-01-31T20:27:00.000-08:00

Y axis getting closer

2010-01-31T20:25:00.001-08:00

Y axis starting to come to gether

2010-01-31T00:05:00.001-08:00

Extruder back plate

2010-01-30T19:32:00.000-08:00

Extruder back plate

2010-01-30T19:31:00.000-08:00

Another significant milestone today

As the build advances so does the drawing

2010-01-30T13:15:00.000-08:00

One step at a time and we will get there.

upside down my burger is burning

Pillow blocks for extruder head

2010-01-29T23:58:00.001-08:00

Some work to go but they are getting closer.

Worm drive fit to motor

2010-01-24T12:23:00.000-08:00

Makerbot Madness at Metrix Create:Space

2010-01-24T06:08:00.000-08:00

A special thanks to Matt and Mathew at Metrix Create:Space. These guys are a warehouse full of knowledge. If you like 3d printing then this is the place in Seattle.

Opto endstops ready to go

2010-01-22T20:33:00.001-08:00

great new mac tools for the makerbot

2010-01-19T10:10:00.001-08:00

http://pleasantsoftware.com/developer/3d/

This application rocks. I am going to keep it handy.

Just one more photo

2010-01-18T18:03:00.001-08:00

This just seemed to capture the moment for me

More z axis parts

2010-01-17T22:15:00.001-08:00

Z axis mounting blocks

2010-01-17T22:14:00.001-08:00

Another part is ready to be mounted to the slate table. Aluminum
block with brass bushings will hold the botom of the z axis acme
screws in place.

Acme threads are all cleaned up

2010-01-17T22:11:00.000-08:00

A little glass bead work and the acme threads from the trash compactor
are ready to be cut and sized

Finally the motors can play music

2010-01-17T22:08:00.001-08:00

Using the tetris motor test run the motors are playing music by
running at different speeds and frequencies

Replicatg is running the x axis stepper

2010-01-09T20:00:00.000-08:00

Now that we have the proper usb to tty cable. The motherboard has begun communicating with the linux computer. Once some test G-code was loaded into the replicatG program the temporarily wired x axis stepper motor began to move. The singing c++ test code did not work but the motor is moving so yahoo! The final assembly of the electronics box will be done tomorrow. This should help keep the electronics safe and secure. While we finish building the robot.

Also the extruder and dual head extruder carriage designs are almost done. More to come on that.

Axis drive parts have arrived

2010-01-05T23:18:00.001-08:00

More Pictures Of The Project

2010-01-04T23:36:00.000-08:00

If you would like to see all the pictures from the project you can find them at the link below. We'll try to posting the interesting ones but all the pictures will be in this gallery.

http://gallery.me.com/bobbhansen#100114

End of the week the thinking is all done

2010-01-03T15:34:00.001-08:00

Final stages of the electronics box

2010-01-03T00:26:00.001-08:00

Cap ready to attach

2010-01-02T22:04:00.001-08:00

Also the x axis rails are epoxied to the stone

Placing the x axis rails

2010-01-01T23:10:00.000-08:00

The robot is coming along now

2010-01-01T23:09:00.001-08:00

Starting to set the x axis

2010-01-01T23:08:00.001-08:00

Best way to find square off the rails

2010-01-01T23:06:00.000-08:00

Going vertical with the build

2009-12-31T23:46:00.000-08:00

electronics and electronics box parts

2009-12-31T08:43:00.000-08:00

Repstrap Parts Under Construction

2009-12-31T08:41:00.000-08:00

Here are a few parts that have been built so far. We are gettign close to an actual assembly now.

Software Installs

2009-12-31T07:40:00.001-08:00

So here is the diagram of how we think all the software fits together.

The second diagram is from replicat.org and was very helpful for understanding How to take 3d designs from the computer to the electronics. One catch is that we didn't know we needed the usb-tty cable so after a few attempts to build one we decided to order it online. Hopefully it get's here before the end of the week. Yes it's a major set back but these types of things are expected. There is plenty of work here so we are just moving on.

The third image is just some install notes for all the software.

2 Paths Under Development

2009-12-31T07:21:00.000-08:00

Now that the base is complete. We are going to start down two paths of development. One path for the software and makerbot electronics and the second for machining and constructing the robot.

Software & Electronics assembly: prior to thinkaweek we gathered up all the hardware for the Ubuntu PC. We also installed Ubuntu and generally had it running. We also placed all of our electronics orders and hoped they would all show up by Christmas.

Robot Construction: Some of the machine work also started prior to thinkaweek but not all of it was done. The main parts to connect the Y axis to the A frames was started, also the Z axis blocks were almost ready. We still need to fit size and place everything so there are a ton of unknowns right now.

Making the Base 2

2009-12-31T07:02:00.000-08:00

Glue screws and a little reinforcement and the base is ready for the 4 foot slate top.

a thin layer of foam stuck down with a super thin layer of double sided tape to take out any leveling problems.

A quick bath and we have the final base made. Rock Solid ! as they say. We kinda like the medieval look it has.

Making The Base

2009-12-31T06:50:00.000-08:00

Just catching up before the build starts

2009-12-23T07:40:00.000-08:00

I thought I would just get some of the drawings, pictures, and notes into the blog as we prepare to build over the Christmas holiday. We have been scrounging and order parts since October in an attempt to have everything we might need to complete the printer by January 1, 2010.

In advance thanks to everyone that has contributed to the Reprap project. Your thinking makes us think.

Advancing Past The Duct Tape Mock Up

2009-12-23T07:24:00.000-08:00

Special Thanks to CR for the drawings.

Stepper Motor Brackets Coming Along

2009-12-23T07:20:00.000-08:00

PLA Roll Has Arrived!

2009-12-23T07:17:00.000-08:00