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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
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 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.  
  
-As of June 10th, this is what it looks like:+As of June 10th, 2012 this is what it looks like:
  
 {{:projects:printer_small.jpg?600|}} {{:projects:printer_small.jpg?600|}}
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-**Update: June 15th**+**Update: June 15th, 2012**
  
 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...
  
-**Update June 17th:**+**Update June 17th, 2012:**
  
 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.  
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 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.
  
-**Update June 19th:**+**Update June 19th, 2012:**
  
 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**
  
 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.
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 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.
  
-Update 4/29/13  MegaMax LIVES!+Update 4/29/2013  MegaMax LIVES!
  
 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!
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 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]]
 +
 +
 +Update: 10/02/2017
 +
 +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.
 +
 +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.
 +
 +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.
 +
 +{{:projects:som.jpg?direct&400|}}
 +
 +You can see and use SoM at the makerspace with about 1 hour of training.
projects/megamax_3d_printer.1367721914.txt.gz · Last modified: 2013/05/05 02:45 by the_digital_dentist

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