RepRap Self Replicating 3D Prototyping Printer

firepinto

RepRap Self Replicating 3D Prototyping Printer
« on September 3rd, 2011, 06:15 PM »
I have been researching the RepRap printers, since Jeff gave the tip. :)  I think it could be important for creating parts for open source projects.  I ordered a kit from ebay for the Prusa Mendel version of the RepRap.  Most of the basic parts are included, just need to get motors, electronics and other parts.  I watched so many Youtube videos trying to see if the parts really would be of any use. lol  I think parts like the EPG dividers could be done with this printer excellently.  Instead of flat dividers they could even be made pie shaped.  
  It sounds like there are multiple 3D programs that can be used to design parts, including Google Sketchup after the file is converted.  I found some people had problems with sketchup not working though.  I've tried a few programs but my patience to learn 3D drawing seems to be really thin! lol  I know there are people here that are way more skilled in the 3D department.:P
  So hopefully I'll have parts soon and can start putting it together.  I'll probably learn to use it trying to replicate Prusa parts.   Eventually I would like to design project boxes for circuits that don't require any holes to be drilled for switches and stuff.  The other thing that I think is interesting is a laser attachment for etching PCB's.:idea:

Nate
RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #1, on September 3rd, 2011, 09:26 PM »
here is a pic of a box made by a reprap:

Jeff Nading

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #2, on September 4th, 2011, 09:44 AM »
Here is a link of full instructions and videos on how to build the Prusa Mendel printer, http://reprap.org/wiki/Prusa_Mendel_Assembly , also, here is a link of a video https://www.youtube.com/watch?v=B3D56IpACME , that is very informative and for people who would like to understand what 3d printing is all about, this should help out quite well to all who would like to build a 3d printer, Jeff.:cool::D
RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #3, on September 5th, 2011, 06:16 AM »Last edited on September 5th, 2011, 06:30 AM by Jeff Nading

firepinto

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #4, on September 5th, 2011, 08:17 AM »
I ordered the RAMPS DIY kit from Ultimachine.  I paid the extra 15 bucks to have the SMT parts pre-soldered.  This is what I have ordered so far, and the damages to the wallet:

EBAY
Prusa Mendel Kit   $168.95
Shipping  $14.95

Amazon
Arduino Mega  $56
Shipping $0

Ultimachine.com
RAMPS DIY Kit + SMT pre-solder  $65
5 NEMA 17 stepper motors, no wire connectors $95
1 lb of black plastic filament $15
1 lb of blue plastic filament $15
shipping $14.95

So far totaling $434.85

I'll be doing some shopping locally for smooth and threaded rods today.  :-)

Jeff Nading

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #5, on September 5th, 2011, 12:09 PM »
Hi Nate, I was doing more reading and found out, [you might know already] that if you use a heated plate you'll also need a separate power supply that will handle the amps, link,  
http://www.ebay.com/itm/120571991063?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649#ht_3368wt_1131
With the electronics you bought, did that include four drivers for the stepper motors, what are you going to use the fifth stepper motor for? Just curious, Jeff.:D

firepinto

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #6, on September 5th, 2011, 03:17 PM »
Quote from Jeff Nading on September 5th, 2011, 12:09 PM
Hi Nate, I was doing more reading and found out, [you might know already] that if you use a heated plate you'll also need a separate power supply that will handle the amps, link,  
http://www.ebay.com/itm/120571991063?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649#ht_3368wt_1131
With the electronics you bought, did that include four drivers for the stepper motors, what are you going to use the fifth stepper motor for? Just curious, Jeff.:D
I actually forgot to order the stepper motor driver boards. :blush:  Ultimachine is out of stock on the ones with heat sinks, now that I look.  The 5th stepper motor is the second Z axis  motor that replaces the drive belt on the previous Mendel version.  It is just wired in parallel with the other Z axis motor, so there is only one driver board needed for the pair.
  I picked up my threaded rods today for $17.57.  I think I'm going to order the smooth rod from McMaster's.  I could of got regular steel rods locally but i read that they recommend drill bit stock because it is smoother.  I had read that too about the second power supply for the heat bed.  I haven't thought that far ahead yet.lol   I do have some ATX supplies here that might work for the printer power.  

Nate

Jeff Nading

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #7, on September 5th, 2011, 03:53 PM »
Say , you are much further along than I am, I just ordered  the Arduino mega, the two steppers I have, can not find any info on them for torque, need to see if I can convert 1.8 degrees/steps = 200 steps per revolution, 2.6 volts, 1.2 amps into torque, I did find out that these motors are unipolar instead of bypolar, have 6 wires instead of four, they are better motors but the Prusa Medal uses the bypolar motors, so I will not be able to use them in this build, oh well they don't cost all that much any way, Jeff.

firepinto

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #8, on September 5th, 2011, 04:57 PM »
Quote from Jeff Nading on September 5th, 2011, 03:53 PM
Say , you are much further along than I am, I just ordered  the Arduino mega, the two steppers I have, can not find any info on them for torque, need to see if I can convert 1.8 degrees/steps = 200 steps per revolution, 2.6 volts, 1.2 amps into torque, I did find out that these motors are unipolar instead of bypolar, have 6 wires instead of four, they are better motors but the Prusa Medal uses the bypolar motors, so I will not be able to use them in this build, oh well they don't cost all that much any way, Jeff.
lol Normally I would be gathering every piece and part to save the most money.  But I want to get this up and going sooner than later.  I want to spend more time learning how to design the parts.:P   I think I'm going to print off my EPG dividers with it.  I can't wait to get something going!  

Nate

Jeff Nading

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #9, on September 5th, 2011, 05:06 PM »
I totally understand, I am the same way, so if you want to buy the heated plate that would be fine with me,  no pressure, that way I can order the plastic parts and get started myself as well, Jeff.

firepinto

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #10, on September 5th, 2011, 05:37 PM »
Quote from Jeff Nading on September 5th, 2011, 12:09 PM
Hi Nate, I was doing more reading and found out, [you might know already] that if you use a heated plate you'll also need a separate power supply that will handle the amps, link,  
http://www.ebay.com/itm/120571991063?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649#ht_3368wt_1131
With the electronics you bought, did that include four drivers for the stepper motors, what are you going to use the fifth stepper motor for? Just curious, Jeff.:D
http://eclecti.cc/hardware/ac-powered-heated-build-platform-for-reprap
This guy made an aluminum bed using resistors in series powered by  120 VAC.  That could cut the cost of buying another power supply.:idea:

Jeff Nading

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #12, on September 6th, 2011, 07:59 PM »
Cool Nate , I am very jealous right now, I ordered the arduino mega board but nothing else as of yet, still researching, I saw the post with the resistors on the bed plate, I'm sure it would work, but would be a little leery that a wire or resistor could fall off short out and take all the electronics with it, of course you could build a cover for it, then insulate the inside. I like the idea of resistance wire, lower voltage to do the same job. Also the stepper motors you bought, was looking at the amp rating of 2 amps with the driver boards also max at 2 amps, wondering if that will be alright that the driver boards don't get to hot, may need a cooling fan, while running they should not pull 2 amps if there is no binding, if all runs smooth you should not have a problem, I'm just thinking and dreaming about it to much I guess, well I am glad you got some of your parts in, I'll order more parts tomorrow, Jeff.:cool::D

txqNL

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #13, on September 8th, 2011, 09:02 AM »
Thats going to be a nice building machine. Have seen some in action and there awesome piece of design.
After when the EPG is printed :P I have some suggestions to print like a very small mighty engine and tube dry cell connectors.
And with a wire nozzle it is easy to create large complex star coils.

~Russ

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #14, on September 8th, 2011, 10:00 AM »
Quote from txqNL on September 8th, 2011, 09:02 AM
Thats going to be a nice building machine. Have seen some in action and there awesome piece of design.
After when the EPG is printed :P I have some suggestions to print like a very small mighty engine and tube dry cell connectors.
And with a wire nozzle it is easy to create large complex star coils.
ooooo, i like the way your thinking! :) ~Russ

firepinto

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #15, on September 8th, 2011, 12:11 PM »
Quote from Rwg42985 on September 8th, 2011, 10:00 AM
Quote from txqNL on September 8th, 2011, 09:02 AM
Thats going to be a nice building machine. Have seen some in action and there awesome piece of design.
After when the EPG is printed :P I have some suggestions to print like a very small mighty engine and tube dry cell connectors.
And with a wire nozzle it is easy to create large complex star coils.
ooooo, i like the way your thinking! :) ~Russ
I like the wire nozzle coil winder idea, could add an epoxy nozzle next to it and have it formed in one shot.  Could use ABS too, but wont handle the heat as well.  I want to make a Rodin coil torus with the guides for the windings built in.  The ideas are stronger than my 3D CAD skills are though! lol  I'll have to use the KISS method for while.  :P

Nate

Jeff Nading

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #16, on September 8th, 2011, 02:48 PM »
Nate have you ordered your hot end yet, if so where did you buy it, I have been looking but I might just make one, I ordered the abs plastic set, same motors you did, UltiMachine has drivers now, I ordered them with the RAMPS and a few other items from them, got bearings, 5/16"  SS althread and 5/16" SS smooth rod, still have a few things to get.

firepinto

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #17, on September 8th, 2011, 03:12 PM »
Quote from Jeff Nading on September 8th, 2011, 02:48 PM
Nate have you ordered your hot end yet, if so where did you buy it, I have been looking but I might just make one, I ordered the abs plastic set, same motors you did, UltiMachine has drivers now, I ordered them with the RAMPS and a few other items from them, got bearings, 5/16"  SS althread and 5/16" SS smooth rod, still have a few things to get.
I haven't ordered mine yet.  The hot end is something I haven't researched enough to know what is a good set up.  I might make one too.  I have enough material here to start building the frame so I'll be working on that today.  Did you go with optical or mechanical end stops on your RAMPS?  I noticed they have little boards for the optos to mount on.  I'm not sure if I can skip using those and just run the opto directly to the RAMPS input.  I think I seen someone do that in a video..

Not sure how the aluminum bed should be made.  I seen one set up that just used sheet metal, and was showing how to bend it straight after peeling parts off.  That don't seem very good.lol   Another set up used large spring paper clips to hold a sheet of glass over the top of the aluminum bed.   I can see how a cast alum. bed would be better with the option of having supports designed into the bottom for strength.  Did you have an idea in mind?

Nate
RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #18, on September 8th, 2011, 04:51 PM »
I was curious if there was anything out there for 3D scanning, so I searched a bit and found this:

http://www.david-laserscanner.com/

There is a free program that can scan with a web camera and a laser pointer.  The second piece of software takes multiple scans (front,sides,back) and stitches them together.  That's the piece that costs some bucks.  But the free software does export in an .obj file, which I found that can be converted to G code that a reprap uses.  Learned something too, things designed in a cad program need to be in millimeters.  Seems that the converting program just assumes everything is metric.  

I wonder how useful it could be for making a 3D fax with the RepRap?  lol I'd love a 3D scan of Stan's WFC plastic parts.  :D

Nate

Jeff Nading

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #19, on September 8th, 2011, 06:13 PM »
http://richrap.blogspot.com/2011/08/pimp-my-mendel-how-to-build-up-lm8uu.html
This is a link to a guy that built his own hot end, very easy, also easy to get parts and very affordable, $10.00 verses $100.00 on Ebay, you can make his version or a square block like others do[one resistor]. If you have access to a lathe you can make the orifice to. I have done some research on the heat plate, I think 3/8" would work after milling, if you were to use glass on top of the plate there is a way you could drill a hole in the edges of the glass to hold it in place with a screw and rubber bushing, but I was thinking I could mill the whole plate, leaving about 1/8" around the edge so as to insert the glass in it, recessed as it were. Plate attachment, I will have to think about and do more research, I'm sure I can come up with something. I am going to go with optical stops, I have some laying around, they are in a plastic housing with a pin connector for each one, looks like the are glued in the housing.The scanning feature, I think would be a wonderful addition to this build, but later on down the road, right now I just want to get my printer up and running. Did you see the SD ramps card Ultimachine has for sell? It's a little steep $35.00 but would be a good upgrade, run parts strait off the card. More to come later.

firepinto

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #20, on September 8th, 2011, 09:16 PM »
Quote from Jeff Nading on September 8th, 2011, 06:13 PM
http://richrap.blogspot.com/2011/08/pimp-my-mendel-how-to-build-up-lm8uu.html
This is a link to a guy that built his own hot end, very easy, also easy to get parts and very affordable, $10.00 verses $100.00 on Ebay, you can make his version or a square block like others do[one resistor]. If you have access to a lathe you can make the orifice to. I have done some research on the heat plate, I think 3/8" would work after milling, if you were to use glass on top of the plate there is a way you could drill a hole in the edges of the glass to hold it in place with a screw and rubber bushing, but I was thinking I could mill the whole plate, leaving about 1/8" around the edge so as to insert the glass in it, recessed as it were. Plate attachment, I will have to think about and do more research, I'm sure I can come up with something. I am going to go with optical stops, I have some laying around, they are in a plastic housing with a pin connector for each one, looks like the are glued in the housing.The scanning feature, I think would be a wonderful addition to this build, but later on down the road, right now I just want to get my printer up and running. Did you see the SD ramps card Ultimachine has for sell? It's a little steep $35.00 but would be a good upgrade, run parts strait off the card. More to come later.
I agree the scanning is much later. lol I think there might be a way to integrate the laser scanner into the Mendel machine.  Depends on the range and speed of motion of the Z axis drive.  The SD card does sound cool.  Would be great for saving electricity normally running the computer.  

I almost finished cutting my rods tonight.  The smooth rods I ordered are definitely a harder steel than the threaded rod.  

Nate
RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #21, on September 9th, 2011, 01:40 PM »
Quote from firepinto on September 5th, 2011, 08:17 AM
I ordered the RAMPS DIY kit from Ultimachine.  I paid the extra 15 bucks to have the SMT parts pre-soldered.  This is what I have ordered so far, and the damages to the wallet:

EBAY
Prusa Mendel Kit   $168.95
Shipping  $14.95

Amazon
Arduino Mega  $56
Shipping $0

Ultimachine.com
RAMPS DIY Kit + SMT pre-solder  $65
5 NEMA 17 stepper motors, no wire connectors $95
1 lb of black plastic filament $15
1 lb of blue plastic filament $15
shipping $14.95

So far totaling $434.85

I'll be doing some shopping locally for smooth and threaded rods today.  :-)
Latest parts:

Fleet Farm (local)
3 foot 5/16" Galvanized Threaded Rod  $17.57

McMaster.com
6 - 8890K41 Tool steel rod 5/16" $25.44 (enough for 2 prusa's)

Makergear.com
HotEnd Pack (.50 mm) $75.00
HotEnd Pack fully assembled option $24.95
HotEnd Pack Wooden mounting  Pieces for Wades extruder $6.00
Shipping $6.82

Ultimachine.com
4- Stepper drivers w/ heatsink $56.00
Kilemen's SD Ramps $35.00
Shipping $10.95

Latest total $692.58
It adds up fast! lol  I should have most of the parts on order needed to make the thing work now.  There is a lot of room to save some money building one of these.  I paid the extra 25 bucks to have the hot end fully assembled.  I'm sure it would take me over an hour to do myself, so that seems like a fair price.  The hot ends look like a PITA to make, and a lot of people seem to like the one from makergear.  Maybe I'll try to make my own version later.  I just want to print.:cool:

Nate
RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #22, on September 12th, 2011, 07:00 PM »
The parts are starting to roll in! :cool:  I've got the Arduino Mega, RAMPS kit, stepper motors, PLA, and bonus PLA from Ultimachine.com.  Was nice of them.:)  I'm really glad I got the SMT parts factory soldered.  The resistors and LED's are like a grain of sand! :P
I'm still putting pieces together, I've found the directions on the RepRap wikki kind of out of order.  The videos don't line up with the directions.  I already have one problem where the smooth rods got finger print rust on them.:rolleyes:  Should of oiled them up.  I think that's going to be a big maintenance issue.   I can tell I'm going to want to build a second one after I learn from this one.  
I hope to make a video this weekend of my progress.

Nate

Jeff Nading

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #23, on September 12th, 2011, 08:17 PM »Last edited on September 12th, 2011, 08:26 PM by Jeff Nading
Quote from firepinto on September 12th, 2011, 07:00 PM
The parts are starting to roll in! :cool:  I've got the Arduino Mega, RAMPS kit, stepper motors, PLA, and bonus PLA from Ultimachine.com.  Was nice of them.:)  I'm really glad I got the SMT parts factory soldered.  The resistors and LED's are like a grain of sand! :P
I'm still putting pieces together, I've found the directions on the RepRap wikki kind of out of order.  The videos don't line up with the directions.  I already have one problem where the smooth rods got finger print rust on them.:rolleyes:  Should of oiled them up.  I think that's going to be a big maintenance issue.   I can tell I'm going to want to build a second one after I learn from this one.  
I hope to make a video this weekend of my progress.

Nate
Hi Nate, all my parts from Ultimachine came in today also, the shield and ramps DIY kits, got the same PLA bonus:cool:,  had ordered some nicrhome insulated wire and thermistor from them to make the hot end, need to order some peek rod though, my Arduino Mega and stepper motors should be here tomorrow. Got my bearings from Ebay. Ya, I have had experience with smooth drill rod before, that's why I went with SS althread and SS smooth cold rolled rod. Waiting on the printed plastic parts, and couplers for the Z axis, link is,  http://www.ebay.com/itm/270814816451?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649#ht_500wt_1076  , still need to order the belts, nuts bolts and washers. My PC Oscilloscope came in today :D:D:cool:. Nate have you done anything with software yet, thought about what you will use, please let me know.  When I cast my aluminum bed plate i'll cast one for you as well,  that's it for now, Jeff.:D

firepinto

RE: RepRap Self Replicating 3D Prototyping Printer
« Reply #24, on September 12th, 2011, 09:13 PM »Last edited on September 12th, 2011, 09:43 PM by firepinto
Quote from Jeff Nading on September 12th, 2011, 08:17 PM
Quote from firepinto on September 12th, 2011, 07:00 PM
The parts are starting to roll in! :cool:  I've got the Arduino Mega, RAMPS kit, stepper motors, PLA, and bonus PLA from Ultimachine.com.  Was nice of them.:)  I'm really glad I got the SMT parts factory soldered.  The resistors and LED's are like a grain of sand! :P
I'm still putting pieces together, I've found the directions on the RepRap wikki kind of out of order.  The videos don't line up with the directions.  I already have one problem where the smooth rods got finger print rust on them.:rolleyes:  Should of oiled them up.  I think that's going to be a big maintenance issue.   I can tell I'm going to want to build a second one after I learn from this one.  
I hope to make a video this weekend of my progress.

Nate
Hi Nate, all my parts from Ultimachine came in today also, the shield and ramps DIY kits, got the same PLA bonus:cool:,  had ordered some nicrhome insulated wire and thermistor from them to make the hot end, need to order some peek rod though, my Arduino Mega and stepper motors should be here tomorrow. Got my bearings from Ebay. Ya, I have had experience with smooth drill rod before, that's why I went with SS althread and SS smooth cold rolled rod. Waiting on the printed plastic parts, and couplers for the Z axis, link is,  http://www.ebay.com/itm/270814816451?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649#ht_500wt_1076  , still need to order the belts, nuts bolts and washers. My PC Oscilloscope came in today :D:D:cool:. Nate have you done anything with software yet, thought about what you will use, please let me know.  When I cast my aluminum bed plate i'll cast one for you as well,  that's it for now, Jeff.:D
That Z axis coupler looks amazing.  Mine is just a printed piece that clamps.  I've been thinking of an idea for a bushing with less friction on rods that aren't so smooth, but that's an idea for later.  :P
I've read about software, but haven't tried any.  I guess there are 3 main bits of software you need.  1) fiirmware uploader 2) Host software 3) Convert 3D to G code.  Number 1 would be the Arduino software.  I don't know all the choices for 2, but I'm going to try Pronterface.  Skeinforge or Sfact are choices for number 3.  I guess Sfact is a very "simplified set up" version of skeinforge.  I'll be trying Sfact, it comes with Pronterface, I think.   I also picked up the SDRAMPS, so I could eliminate some of that.  :)  
The aluminum bed I think is going to be a great addition.  :)  A huge thanks for making me one.   Are  ya going to still want to trade for printed parts if you ordered some?  We could come up with something different otherwise.  

Nate

I found another source for those couplers:

http://www.aliexpress.com/store/201108/210082157-458122907/5pcs-lot-A101-5mm-to-8mm-CNC-Stepper-Motor-Flexible-Coupling-Coupler-5-x-8mm.html

The come in packs of 5, and would be cheaper.  That is if we really needed 5 of them lol.  I imagine that is where the ebay seller gets them from.  They look like a high quality item.  Might be my first upgrade after its up and running.  

I seen a video (wish I could find it now) that a guy modified his prusa so that he had 608 bearings taking the weight of the threaded rod.  He had his stepper motors jacked up with a different printed coupler between the 608 bearing and the motor.  It was an interesting idea that seems like it has good reasons.  I don't know how good stepper motor bearings are, but I bet he's right in thinking they don't work well as thrust bearings.


Nate