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projects:megamax_3d_printer [2013/05/05 02:45] the_digital_dentist |
projects:megamax_3d_printer [2017/10/02 16:31] (current) the_digital_dentist |
Plastic extrusion type 3D printer with approximately 1 cuft build envelope. My goal is to print life-sized human skulls from CT scan data. The machine uses 80/20 type aluminum extrusions for the frame and many scrounged parts generously supplied by the hack-rack, Tom G., and others at the makerspace. The design is loosely based on the MendelMax (Y-axis base, extruder on X-axis boom lifted by Z-axis screws), but I am sort of designing/cobbling as I go, one axis at a time, and fabricating parts as needed to fit the other pieces I have in-hand. | Plastic extrusion type 3D printer with approximately 1 cuft build envelope. My goal is to print life-sized human skulls from CT scan data. The machine uses 80/20 type aluminum extrusions for the frame and many scrounged parts generously supplied by the hack-rack, Tom G., and others at the makerspace. The design is loosely based on the MendelMax (Y-axis base, extruder on X-axis boom lifted by Z-axis screws), but I am sort of designing/cobbling as I go, one axis at a time, and fabricating parts as needed to fit the other pieces I have in-hand. |
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As of June 10th, this is what it looks like: | As of June 10th, 2012 this is what it looks like: |
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{{:projects:printer_small.jpg?600|}} | {{:projects:printer_small.jpg?600|}} |
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**Update: June 15th** | **Update: June 15th, 2012** |
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I have fabricated the pulley for the far end of the X-axis, and the belt and drive pulley for the Z-axis screws arrived today. Looking forward to some simple motion tests this weekend. Working on the print platform design tonight... | I have fabricated the pulley for the far end of the X-axis, and the belt and drive pulley for the Z-axis screws arrived today. Looking forward to some simple motion tests this weekend. Working on the print platform design tonight... |
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**Update June 17th:** | **Update June 17th, 2012:** |
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The alignment technique for the X-axis guide rails worked as planned- I screwed an aluminum plate to the bushing blocks at the non-adjustable end of the guide rails then slid the assembly to the other end and tightened the screws that hold the guide rails. Next I cut and mounted the belt and it seems like I get very smooth motion all the way across the X-axis. | The alignment technique for the X-axis guide rails worked as planned- I screwed an aluminum plate to the bushing blocks at the non-adjustable end of the guide rails then slid the assembly to the other end and tightened the screws that hold the guide rails. Next I cut and mounted the belt and it seems like I get very smooth motion all the way across the X-axis. |
I made a plate to mount on the Y-axis bushing blocks and found that the end pieces that hold the guide rails do not allow for easy adjustment of their positions. I'm going to redesign and fabricate the Y-axis guide rail end plates, possibly today. | I made a plate to mount on the Y-axis bushing blocks and found that the end pieces that hold the guide rails do not allow for easy adjustment of their positions. I'm going to redesign and fabricate the Y-axis guide rail end plates, possibly today. |
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**Update June 19th:** | **Update June 19th, 2012:** |
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I made a test plate for the Y axis, made a new mount for the Y-axis guide rails, installed a belt on the Y-axis, widened the slots for the belt on the X-axis. | I made a test plate for the Y axis, made a new mount for the Y-axis guide rails, installed a belt on the Y-axis, widened the slots for the belt on the X-axis. |
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**Update August 12th** | **Update August 12th, 2012** |
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Above listed problems have been fixed. Electronics ordered, delivered, connected and tested. Problem: Marlin firmware flashed on controller board not really suitable for my printer. Solution: download Marlin, modify config.h and pins.h files, compile, and update firmware on controller board. New problem: Marlin will not compile with latest Arduino IDE. Solution: spend a week chasing problems and get nowhere. Real solution: go to 3D printing meet-up at Bucketworks, hope someone has mercy on me and can help get it working. As luck would have it, Gary Kramlich was present and has much better kung-fu than I. In 5 minutes he had located the issue, fixed it, and I was able to update the firmware. It turns out the IDE had a macro that defined a mathematical "round" function which was in conflict with the round function in the math library of the C compiler. Commenting out the macro in the IDE allowed it to compile the firmware. | Above listed problems have been fixed. Electronics ordered, delivered, connected and tested. Problem: Marlin firmware flashed on controller board not really suitable for my printer. Solution: download Marlin, modify config.h and pins.h files, compile, and update firmware on controller board. New problem: Marlin will not compile with latest Arduino IDE. Solution: spend a week chasing problems and get nowhere. Real solution: go to 3D printing meet-up at Bucketworks, hope someone has mercy on me and can help get it working. As luck would have it, Gary Kramlich was present and has much better kung-fu than I. In 5 minutes he had located the issue, fixed it, and I was able to update the firmware. It turns out the IDE had a macro that defined a mathematical "round" function which was in conflict with the round function in the math library of the C compiler. Commenting out the macro in the IDE allowed it to compile the firmware. |
Once I have the extruder mounted I'll have to calibrate everything and that will mean updating the firmware again, but that's a pretty easy process now. | Once I have the extruder mounted I'll have to calibrate everything and that will mean updating the firmware again, but that's a pretty easy process now. |
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Update 4/29/13 MegaMax LIVES! | Update 4/29/2013 MegaMax LIVES! |
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After a long hiatus for a home move, a makerspace move, and various other distractions, I was able to get back to work on MegaMax and managed the first print on it today! | After a long hiatus for a home move, a makerspace move, and various other distractions, I was able to get back to work on MegaMax and managed the first print on it today! |
Here's some video of the first print in progress: | Here's some video of the first print in progress: |
[[http://vimeo.com/65081537|MegaMax first print]] | [[http://vimeo.com/65081537|MegaMax first print]] |
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| Update: 10/02/2017 |
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| MegaMax was mostly a success and was finished about 4 years ago (I should really update the wiki more often). However, one of the original goals was to print ABS and after building MegaMax I learned that the printer needs to be enclosed and kept warm to print ABS reliably. That resulted in a complete redesign so MegaMax was torn apart and a lot of the materials were reused to make Son of MegaMax which has been residing at the makerspace for about 2 years. |
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| Son of MegaMax has the same print envelope, but is fully enclosed, uses a Smoothieboard 32 bit controller, has electronics located in a drawer in the base of the printer, has a BullDog XL extruder and E3D v6 hot-end, and now uses linear guides in the X and Y axes instead of round guide rails. The Y axis is driven by a ball screw instead of a belt. |
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| Somewhere along the way I figured out how to make a stable 3 point leveling system and used cast aluminum tooling plate for the bed. |
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| {{:projects:som.jpg?direct&400|}} |
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| You can see and use SoM at the makerspace with about 1 hour of training. |