Almost there..

Been a while since I've worked on the machine but it's nearly there. All the software and firmware is setup and just a few final touches to the mechanics of the machine to go. I've had it dry-running a complete job and seems to work fine. 

The heating elements for the nozzle have just arrived from the UK so I have machined a copper heating block for heating the nozzle. 

Heating block with element.

Underside of Assy.

PEEK insulator / PTFE Liner / PEEK Insulator / 464 (Lead Free) Brass Nozzle /  110 (High Conductivity) CU Heating Block

Nearly there..

Haven't updated this for a while, a lot of work has been done. Nearly all of the mechanics of the machine are completed. Limit switches on all axes, stepper drivers for all axes wired up, belt tensioners and drive systems completed. All that's remaining is to mount the heated bed and manufacture the nozzle heater assembly. 

I have the control side of the machine to sort out. I have an IBM Thinkpad laptop to use with it, but am struggling with the software side of things at the moment.

Here's a short video of a test program running on the machine.

It Lives!!

A lot of work has been done over the Xmas break and I've finally got the Z-Axis working using a test program which cycles all axes.

I've used an Audrino Mega 1280 with RAMPS 1.4 Sheild and wired from this to external Gecko G251 Stepper Drives. Only one stepper driver is fitted so far as I wanted to test that it would actually work before purchasing all four.

A few things still to do;

Limit switches on all axes
X belt idler
Waiting for 2x more stepper motors to arrive
Waiting for 3x gecko drives to arrive
Machine heated bed
Belt tensioners for extruder
Extruder nozzle heater and thermistor

More progress, eBay linear rails have arrived and are all mounted up to machine. Extruder head is mounted. Work left is to finish X and Y belt drives, make heated bed and insulators, Ballscrew nut mount, and wiring.

More progress, the extruder design is 90% finished, only the drive pulleys and belt to complete. The machine frame is almost done, uprights, sides and support parts all finished. Still awaiting on the linear rails to arrive from eBay so I can mount the table and saddle assemblys.


I chose to mount the Y drive motor under the machine to allow more travel in the Y direction. The table will slide over where the drive pulley is mounted.


I'm still trying to figure out the heating elements for the extruder. Really want to know what works the best and what power supply etc I need?

PEEK components machined for extruder.

Base machined.

Bit more progress, I've machined the base square and added holes for uprights and underneath supports. I'm still waiting for CNC mill time at work to skim the top and bottom of the base plate.

 The extruder has had a bit of work, the rollers I had setup with a heavy spring to provide gripping force onto the filament, I've done tests and found it to only hold a force of around 40N, so have added two SMC single action cylinders to push directly onto the roller shaft that provides force onto the filament. This gives considerably more force, which is adjustable by adjusting the pressure available to the cylinders, and will make changing the filament much easier as I can release pressure off it. I'll do more tests and hopefully this setup will provide enough clamping force.

Extruder showing SMC cylinders added to provide force onto feed rollers.

Machine base, bed, upright supports machined.

Extruder setup showing brass 0.5 nozzle and machined teflon liner.

Extruder, awaiting drive pulleys and belt.

Bit for work done on the extruder body. Waiting on linear bearings and stepper motors from the states, T5 belts and pulleys from Saeco and machine time in one of the mills at work to get the base machined.