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Δ3D Build-log

Posted by DannerD3H 
Δ3D Build-log
August 06, 2017 07:38AM
Δ3D and Why

Hello people!
Meet the Δ3D (as it looks at this point)



Now that I (hopefully) got your attention, all the boring stuff tongue sticking out smiley
I love to design things and tinker, I always have! The last couple of years I have been using 3D printers quite a lot and gathered quite some experience in the field. My first experience with 3D printers was a MakerBot Replicator 2. Later I got myself a Prusa i3. I learned a lot from this machine and it is still producing really nayz prints for the cost of the machine. My latest 3D printer experience though is the most.. well.. interesting one. An AirWolf 3D AXIOM printer.. Luckily I didn’t buy it, or advise any to do so, I just happened to get stuck with it. However, over the last two years this machine have taught me so much about 3D printing.. at least how it should NOT be done!

I have been tempted to build a 3D printer for a long time.. just for the fun, learning and experience of it. A few months ago, I really started designing my own printer and now it is actually getting somewhere. So I decided to create this blog before I got to far for it to make sense! I create this blog mainly because I love these forums, I love to get inspiration from other people’s builds – Thus I want to share my build in case others find it inspiring. The project is a spare time project, I will be posting news when there are any, but it may take a while before the printer is finished.. Meanwhile, enjoy this build-log of my homemade delta style 3D printer. For now, I call it Δ3D. Very original, I know, but I am really bad with finding names..

LETS GET ON WITH IT! smiling bouncing smiley

Edited 5 time(s). Last edit at 08/06/2017 07:49AM by DannerD3H.
Δ3D Build-log
August 06, 2017 07:46AM
1. My design

I have chosen the Delta platform and I’m not going to lie about it.. I choose it because I think they look F****** amazing! Especially when printing!!
I have been reading a lot about Delta printers and DIY projects of such. I have gathered inspiration from many printer designs out there, but among others are the Kossel, Hexagon V2, Hexagon XL, Hexagon by Protoprinter and the ATOM printer to make a few honorable mentioning’s.

Before I begun I put down a few design requirements:
1. Silence! – The singing from a MakerBot stepper motors or PSU fan noise of the AXIOM is killing me!
2. The visual is more important than economy(within reason), after all I will only be building one.
3. It must be easy to modify – The first design is undoubtable going to be modified..
4. Quality over speed – The goal is to compete with Ultimaker print quality.. One gotta aim high! tongue sticking out smiley
5. Build area must be bigger than my Prusa I do not care much about build height, never used the Prusa’s 200 mm of height anyway but often needed one dimension above 200 mm.
6. Build area must be easily enclosed without affecting build area or hurt the design.
7. Dual extrusion must be possible in full build area also if build chamber is enclosed. Dual extrusion is only intended for support material, I won’t do much if any multicolor printing.
8. The printer must be as small as possible without compromising any of the above – or in other words, our apartment is not huge so it must be Girlfriend friendly tongue sticking out smiley

I have access to two working 3D printers, a workshop with a manual lathe and milling machine. At occasions, I also have access to a CNC mill. The design will mostly relay on 3D printing and manual work, but a few critical parts will be in aluminum from the CNC.

Some of my general design choices explained:
1. Hexagon shaped printer – Smaller footprint than triangle when considering enclosure.
2. 20x20 extrusion – I don’t want a super tall machine so stiffness should be okay as I have 5 towers in the worst case I will brace the frame with diagonal carbon rods.
3. Ø310 mm print bed – Bigger than the Prusa, availability and for now I use the heatbed of the Rostock Max V3, but the design will be prepared for a Mains silicone heater as an iteration.
4. 0.9 degree stepper motors – Higher accuracy over speed
5. 24V power supply – Fast heating times, Faster and stronger stepper motors and lower currents in general.
6. Smoothieboard V2 (will hopefully be released soon) – Just sounds like a great 32 bit controller! And suuper high microstepping 1/256. This will greatly reduce stepper motor noise! The controller also easily allows for added features like laser engraving.
7. Safety – No exposed WIRES (especially not mains). I am clumsy and already replaced my Prusas Ramps controller twice because of my clumsiness and stupidity..
8. Single nozzle dual extrusion Prusa/ATOM style! – No oozing issues, no Z calibration of two nozzles. Downside is more wasted material though.

My biggest remaining dilemma is the extruder.. I want to make the Bowden tube as short as possible. I just have not figured out if I should use a stationary extruder as close to the hotend as possible, which I have shown in my first post, or if I should use a flying extruder. If I go with the stationary extruder, I could mount both in the chamber. If I choose a flying extruder I would only have the main extruder flying. The support extruder I would keep remote with a longer Bowden tube.

The design will be explained in more detail as the build gets along!
Re: Δ3D Build-log
August 06, 2017 12:53PM
Quote
DannerD3H
6. Smoothieboard V2 (will hopefully be released soon) – Just sounds like a great 32 bit controller! And suuper high microstepping 1/256. This will greatly reduce stepper motor noise!

I'm biased, but why not a Duet WiFi, which uses the same stepper motors that Smoothieboard 2 is supposed to be going to use, but has already been available for a year? Plus you get a better web interface and least squares delta auto calibration. Or the Duet Ethernet if you prefer a wired connection.

I can't fault most of your other design choices. The 5-verticals approach allows the possibility of adding 2 more carriages to mount the extruders on, so that they can move with the effector and allow shorter Bowden tubes. This is a configuration that we're planning to support soon in RepRapFirmware.

Edited 1 time(s). Last edit at 08/06/2017 12:56PM by dc42.

Delta printer calibration calculator, mini IR Z probe, and colour touch screen control panel: [escher3d.com]

Large delta printer, and other 3D printer blog postings: [miscsolutions.wordpress.com]

Full disclosure: I have a financial interest in sales of the Panel Due, Mini IR height sensor, and Duet WiFi/Duet Ethernet.
Re: Δ3D Build-log
August 07, 2017 05:58AM
I was also biased on the smoothieboard smiling smiley
BUT you actually have a very good point. It is risky to use a brand new product compared to one that has been out there for a year. I will have a closer look at that controller that is for sure!

Oh that is interesting! Dind't know something like that was out there! will look out for that!
Re: Δ3D Build-log
August 07, 2017 01:05PM
Quote
DannerD3H
I was also biased on the smoothieboard smiling smiley
BUT you actually have a very good point. It is risky to use a brand new product compared to one that has been out there for a year. I will have a closer look at that controller that is for sure!

Oh that is interesting! Dind't know something like that was out there! will look out for that!

More on the series 2 Duets can be found at [www.duet3d.com]. There is a support forum at [www.duet3d.com].

Don't get me wrong, I think Smoothieboard 1 was a good board for its time (I considered distributing it at one point) and I expect Smoothieboard 2 will be good when it eventually arrives, assuming that doesn't take so long that technology overtakes it first. Although for 3D printer control, I think Smoothieware has some catching up to do to equal RepRapFirmware.

Edited 2 time(s). Last edit at 08/07/2017 02:29PM by dc42.

Delta printer calibration calculator, mini IR Z probe, and colour touch screen control panel: [escher3d.com]

Large delta printer, and other 3D printer blog postings: [miscsolutions.wordpress.com]

Full disclosure: I have a financial interest in sales of the Panel Due, Mini IR height sensor, and Duet WiFi/Duet Ethernet.
Re: Δ3D Build-log
August 07, 2017 03:14PM
If your trying to build a top end 3dprinter don't skimp on the electronics. I have the Duet Wifi and could not be happier. I can't imaging building another printer without purchasing a DuetWfif. If your trying to save a bit of money, you can skip out on the Panel Due as the web interface that comes with the DuetWifi works seamlessly.
Re: Δ3D Build-log
August 08, 2017 05:38AM
good design but for the frame you should realize by yourself
Re: Δ3D Build-log
August 08, 2017 08:04AM
Hmm.. I really liked the documentation on the Smoothieboard V1, but i also didn't like that it wasn't reprap firmware, as that is what i am used to. I am still investigating further, i will still take some time before i have to choose tongue sticking out smiley
#Qdeathstar; Do you know if i can use the MKS tft32 display with the Duet? I would really like to use a touch screen with a pretty interface. I was also considering the Viki 2 LCD, but would prefer a touch screen.

#Titeuf007; what should i realize?
Re: Δ3D Build-log
August 08, 2017 10:27AM
2. 3D print-ception

One of the best things about 3D printers are that they can produce parts for them self or other printers! grinning smiley


I have been printing parts for my delta printer for a while now. I have actually almost printed the first iteration of all parts., Quite a pile of plastic.. roughly 2 kg of PETG (including brims, rafts and so on).


As you can see, my design is not really suited for replication or certainly not mass production as the bare frame alone contains 30 3D printed parts. For the entire printer that number is closer to 70. Maybe not such a great design with all these printed parts, but I am still confident that the frame will be stiff enough due to the design and the three 4 mm aluminum plates I will have laser cut… somewhere.. will eliminate all flex from plastic corners.
I have also generally chosen to rather print more, smaller parts than fewer bigger parts. So compared to a Kossel which have 6 corner parts in total I have 24. I could have made 12 (hexagon) big ones instead of course, but by making 24 I have less risk of failing prints or at least shorter prints and more design/print flexibility. The frame alone (only structural parts) are roughly 120 hours of printing confused smiley

Every structural part have been printed to optimize stiffness and strength with the print settings:
Material: PETG from DasFilament (some – the matte ones – are XT from ColorFabb though)
Layer height: 0.2 mm
Perimeters: 4
Top and bottom thickness: 1.6 mm
Infill: 35 %
Speed: 35 mm/s

All corner pieces are printed with brim and additional “Plates” to completely eliminated warping and ensure flatness. Before and after post processing picture of a top corner:


So far, I am missing four parts before I can assemble the frame! .. Yeah my priority of prints may not have been the best.. Should have finished the frame parts first.. but I didn’t have the 20X20 extrusions in the beginning, and wanted to ensure a good fit. They also have to be cut btw...

Print! Print! Print!..

Edited 1 time(s). Last edit at 08/08/2017 10:30AM by DannerD3H.
Re: Δ3D Build-log
August 08, 2017 12:26PM
great
so impatient to see the result
Re: Δ3D Build-log
August 08, 2017 02:37PM
Quote
DannerD3H
Hmm.. I really liked the documentation on the Smoothieboard V1, but i also didn't like that it wasn't reprap firmware, as that is what i am used to. I am still investigating further, i will still take some time before i have to choose tongue sticking out smiley
#Qdeathstar; Do you know if i can use the MKS tft32 display with the Duet? I would really like to use a touch screen with a pretty interface. I was also considering the Viki 2 LCD, but would prefer a touch screen.

Documentation for the Duet is at [duet3d.com]. The Duet doesn't support the MKS display, instead it supports a display controller that can be used with a 4.3, 5 or 7 inch touch screen. You even get an on-screen keyboard so that you can enter gcode commands directly if you want. See [miscsolutions.wordpress.com].


Delta printer calibration calculator, mini IR Z probe, and colour touch screen control panel: [escher3d.com]

Large delta printer, and other 3D printer blog postings: [miscsolutions.wordpress.com]

Full disclosure: I have a financial interest in sales of the Panel Due, Mini IR height sensor, and Duet WiFi/Duet Ethernet.
Re: Δ3D Build-log
August 09, 2017 05:27AM
#dc42
I have been reading a little about the Duet now, and i definitely also like that board and documentation. I still didn't decide yet though. My first impresion is that the Duet has more features/flexibility, but it also feel slightly more complex to use. But that is a first impression, I am still way more into the Smoothie way of doing it (not saying it is better).
Do you know if you can limit the PWM to the bed? I do plan on using a mains bed and a SSR eventually, but for a start i have the 12V PCB heater from the Rostock max V3 lying around, but using that one with 24V power requires to limit the bed PWM signal. And i am going to use 24V power.
Also, is it possible to modify the Paneldue's GUI? I like the features of it but certainly not the look of it..

#titeuf007
Not good.. it may take a while xD

Edited 1 time(s). Last edit at 08/09/2017 05:27AM by DannerD3H.
Re: Δ3D Build-log
August 09, 2017 02:56PM
I'm a smoothie convert. Once you get used to specifying everything using the G-Code commands I'd say it is just as easy but yes there is some learning to switch to the Duet terminology and commands. I've found that once you are onboard with Duet most things are much easier to work out. David does a pretty good job of taking the concept and making it so you do not have to have a PhD to figure it out (delta leveling for instance). I found that while the write-ups in Smoothie were nice I never did get Delta calibrations and Z-Height adjustments work as well as I have them on the Duet.

Smoothie is a good setup also, I just found that my thinking seems to align better with RepRapFirmware's way of thinking about stuff. My end results have been better with less frustration since switching to RepRapFirmware.
Re: Δ3D Build-log
August 09, 2017 04:05PM
Quote
DannerD3H
#dc42
I have been reading a little about the Duet now, and i definitely also like that board and documentation. I still didn't decide yet though. My first impresion is that the Duet has more features/flexibility, but it also feel slightly more complex to use. But that is a first impression, I am still way more into the Smoothie way of doing it (not saying it is better).

There is a learning curve involved in switching to any 3D printer firmware that you are not already familiar with. The Smoothie way of configuring everything in in a text file is good. RRF does the same, but the commands are all gcodes. One advantage of this is that you can make any configuration change you like in the fly (except change the network MAC address) to try it out, without having to reboot the board.

Quote
DannerD3H
Do you know if you can limit the PWM to the bed? I do plan on using a mains bed and a SSR eventually, but for a start i have the 12V PCB heater from the Rostock max V3 lying around, but using that one with 24V power requires to limit the bed PWM signal. And i am going to use 24V power.

Yes you can limit the PWM. The bed heater output of the Duet is rated at 18A RMS so take care not to exceed this if you use a 12V heater with a 24V supply.

Quote
DannerD3H
Also, is it possible to modify the Paneldue's GUI? I like the features of it but certainly not the look of it..

You can choose between light and dark colour schemes as standard. The firmware is open source, so if you are into C++ programming you can make whatever changes you like to it.

HTH David

Edited 2 time(s). Last edit at 08/09/2017 04:06PM by dc42.

Delta printer calibration calculator, mini IR Z probe, and colour touch screen control panel: [escher3d.com]

Large delta printer, and other 3D printer blog postings: [miscsolutions.wordpress.com]

Full disclosure: I have a financial interest in sales of the Panel Due, Mini IR height sensor, and Duet WiFi/Duet Ethernet.
Re: Δ3D Build-log
August 16, 2017 11:13PM
Just a quick update..

I am really busy at the moment, but i have printed 3 of the remaining 4 parts and i have received the last aluminum extrusions. So i will soon cut the aluminum and assemble the frame!


Thanks for the inputs DC42 and WZ9V.
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