Hi, I am new to this forum but I felt to create an account and share this linear movement solution I created. A few months ago I set out to custom build a new I3 style printer, out of an older and discarded machine. I decided to use 2040 extrusions because of its rigidity and the project worked out pretty well. While building, I learned a lot about linear movement and it basically almost always comes down to a bearing system fastened on top of a frame, where you see that the two functions (construction and movement) are handled by separate physical components (frame and linear bearings). It dawned to me that the extrusions I was working with have these nice slots running over the full length and I started to wonder if I could integrate the construction and movement functions into 1 component: the aluminium extrusion itself. After some experimenting and iterating, I came up with a working system which uses 4 of the 6 slots. It is very low on backlash as the 4 sliders compensate one another greatly. Further, because the little backlash, the fit is quite tight and to compensate I applied a bit of bearing grease to the slider and the slot itself. Finally, the moving carriage is fashioned with a piece of 4mm aluminum rod over the full length. This makes the carriage to mainly run metal to metal (with grease in between). The plastic is there, mainly for keeping the metal in the right place. You can see the proof of concept working here: [www.instagram.com] After this working proof of concept, I decided to use my custom I3 as the guinea pig. I redesigned the z axis to get rid of the 8mm aluminium rod and added the slot carriage to it. First, I did one side, with the original system remaining on the other side. After this proved to be successful, the other side was updated as well. After just minor fine tuning, the machine worked again. And to be honest, it is better at layer consistency than it was before. You can see the I3 in action here: [www.instagram.com] A couple of advantages of this system: - It is more compact than a traditional system. - It is quiet, as there are no bearing balls moving all the time - It is durable for the same reason as above - It is far cheaper than traditional systems - I now have 2, 8mm rods that I have reused to further strengthen my frame B) I am very curious about what the community thinks of this idea. I am looking forward to your input and questions, and see if it can be improved further. Hopefully the I3 can be upgraded on the X and Y axis as well in the future. https://reprap.org/forum/read.php?177,874245,874245#msg-874245 Sun, 12 Jul 2026 01:30:40 -0400 Phorum 5.2.23 https://reprap.org/forum/read.php?177,874245,878609#msg-878609 https://reprap.org/forum/read.php?177,874245,878609#msg-878609 www.instagram.com].

The new printer is running very smooth, silent and the sliders are doing their job well.]]> joostvl Extruded Aluminum Frames Fri, 06 Nov 2020 17:59:05 -0500 https://reprap.org/forum/read.php?177,874245,878383#msg-878383 https://reprap.org/forum/read.php?177,874245,878383#msg-878383 joostvl Extruded Aluminum Frames Wed, 28 Oct 2020 08:12:42 -0400 https://reprap.org/forum/read.php?177,874245,878382#msg-878382 https://reprap.org/forum/read.php?177,874245,878382#msg-878382
You can see the mechanism here: [vimeo.com]

Here's a picture of the bearing/pulley blocks. One has two, 3 mm steel pins that the bearing slides on, and springs that fit over each pin that push the bearing.

[attachment 117015 Yaxisbearingblocks.jpg]

I wouldn't recommend it for a 3D printer, but it's fine for a sand table where resolution in the sand is 2-3 mm at best.]]> the_digital_dentist Extruded Aluminum Frames Wed, 28 Oct 2020 07:57:51 -0400 https://reprap.org/forum/read.php?177,874245,878381#msg-878381 https://reprap.org/forum/read.php?177,874245,878381#msg-878381 By the way, in the solution I proposed. the slider is also rigged with an aluminum rod inside of it, resulting in extra strength and metal on metal sliding.

Of course I hope I won't be facing such problems so thanks for sharing your experience!]]> joostvl Extruded Aluminum Frames Wed, 28 Oct 2020 06:26:35 -0400 https://reprap.org/forum/read.php?177,874245,878365#msg-878365 https://reprap.org/forum/read.php?177,874245,878365#msg-878365
I am now rebuilding the sand table as a coffee table in a slightly smaller size. The rebuild includes a redesign of the bearing/pulley blocks that include the PTFE bearings.]]> the_digital_dentist Extruded Aluminum Frames Tue, 27 Oct 2020 15:13:50 -0400 https://reprap.org/forum/read.php?177,874245,878363#msg-878363 https://reprap.org/forum/read.php?177,874245,878363#msg-878363 VDX Extruded Aluminum Frames Tue, 27 Oct 2020 13:37:56 -0400 https://reprap.org/forum/read.php?177,874245,878361#msg-878361 https://reprap.org/forum/read.php?177,874245,878361#msg-878361
The sliders are still doing very well and I get consistent prints without any noticeable artifacts on the Z axis. When it comes to dirt, potentially grinding in the rails, I haven't had that problem so far. Although I do appreciate that being a risk of this technique as MKSA fairly commented.
Of course, the Z-axis on an I3 type printer is not moving as much as the X and Y axis. Still, I am pleased with the current performance.

To put this to the real test, I am now building a huge Delta printer (107 cm high) and I am going to apply this slider technique to it. This will of course generate a lot more (quick) movements and I am really curious how it will cope :).]]> joostvl Extruded Aluminum Frames Tue, 27 Oct 2020 13:27:21 -0400 https://reprap.org/forum/read.php?177,874245,877101#msg-877101 https://reprap.org/forum/read.php?177,874245,877101#msg-877101 Ohmarinus Extruded Aluminum Frames Wed, 09 Sep 2020 08:31:52 -0400 https://reprap.org/forum/read.php?177,874245,874253#msg-874253 https://reprap.org/forum/read.php?177,874245,874253#msg-874253
Do you happen to have a link to this product or concept? I am not familiar with Igus.

Edit: I think I found what you mean as it fits your description: [www.igus-cad.com]
I don't think that this is conceptually the same as this Igus system is also placed on top of the extrusion and not integrated in its properties.

I have been doing quite extensive searching before but couldn't find anything similar. Thanks for you (no) grease tip by the way.]]> joostvl Extruded Aluminum Frames Thu, 25 Jun 2020 13:05:27 -0400 https://reprap.org/forum/read.php?177,874245,874249#msg-874249 https://reprap.org/forum/read.php?177,874245,874249#msg-874249 In fact better use the 8mm rods nested in the Al profile as tracks. The type of anodization of these Al profiles is usually not suitable for a track.
Of course Igus filament ot make proper sliders too. And NO GREASE, it is messy, collect debris and acts as grinding paste.]]> MKSA Extruded Aluminum Frames Thu, 25 Jun 2020 12:53:43 -0400 https://reprap.org/forum/read.php?177,874245,874245#msg-874245 https://reprap.org/forum/read.php?177,874245,874245#msg-874245
I am new to this forum but I felt to create an account and share this linear movement solution I created.

A few months ago I set out to custom build a new I3 style printer, out of an older and discarded machine. I decided to use 2040 extrusions because of its rigidity and the project worked out pretty well. While building, I learned a lot about linear movement and it basically almost always comes down to a bearing system fastened on top of a frame, where you see that the two functions (construction and movement) are handled by separate physical components (frame and linear bearings).

It dawned to me that the extrusions I was working with have these nice slots running over the full length and I started to wonder if I could integrate the construction and movement functions into 1 component: the aluminium extrusion itself.

After some experimenting and iterating, I came up with a working system which uses 4 of the 6 slots. It is very low on backlash as the 4 sliders compensate one another greatly. Further, because the little backlash, the fit is quite tight and to compensate I applied a bit of bearing grease to the slider and the slot itself. Finally, the moving carriage is fashioned with a piece of 4mm aluminum rod over the full length. This makes the carriage to mainly run metal to metal (with grease in between). The plastic is there, mainly for keeping the metal in the right place.
You can see the proof of concept working here: [www.instagram.com]

After this working proof of concept, I decided to use my custom I3 as the guinea pig. I redesigned the z axis to get rid of the 8mm aluminium rod and added the slot carriage to it. First, I did one side, with the original system remaining on the other side. After this proved to be successful, the other side was updated as well. After just minor fine tuning, the machine worked again. And to be honest, it is better at layer consistency than it was before.
You can see the I3 in action here: [www.instagram.com]

A couple of advantages of this system:
- It is more compact than a traditional system.
- It is quiet, as there are no bearing balls moving all the time
- It is durable for the same reason as above
- It is far cheaper than traditional systems
- I now have 2, 8mm rods that I have reused to further strengthen my frame B)

I am very curious about what the community thinks of this idea. I am looking forward to your input and questions, and see if it can be improved further. Hopefully the I3 can be upgraded on the X and Y axis as well in the future.]]> joostvl Extruded Aluminum Frames Thu, 25 Jun 2020 10:45:44 -0400