1X2

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Revision as of 14:38, 21 September 2011 by Mrkim (talk | contribs) (360 bearing v2.0:)
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1X2

Release status: Experimental

Mrkim-reprap-1X2-4676.JPG
Description
Perky Wooden RepStrap
License
Author
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Description:

Mrkim-reprap-1X2-4676.JPG

The 1X2, 1X2 Shortcat, and 1X2 Tallcat are Reprap class 3D-printers that can be built with access to only a drill-press and hand-saw. The parts for the entire system can be made with one-dimensional tools, straight cuts and common materials.

This machine is made by: mrkimrobotics.com

Status Summary:

Working Status:
The 608 linear bearing system works well and is mature.
The shaft-couplers for leadscrews and axles work well.
The 1X2 vertex frame system has worked well.
The Scoop Extruder has printed continuously for many hours with no issue.
The flat belts themselves are strong, efficient and easy to construct.

Experimental Status:
Consistently countering "belt creep" with non-slipping elastic flat-belts in open-loop control as a function of speed remains an issue of study.

  • The 'Droftarts method' homes X and Y between each layer to correct for creep/crawl drift.
  • If someone wants to try a linear magnetic sensor on the conveyor-belt for absolute positioning, post your results here.

Features:

  • It has a printable area greater than all of its parts(including the rods).
  • Dual-head extruder and plotter(w/ hot and cold separation).
  • Simultaneous extrusion and plotting.
  • Quick-change plotter head.
  • Narrow x-carriage design.
  • It uses only 608 bearings.
  • It uses only 5/16" bolts.
  • It uses all 1-unit length rods.
  • It uses all DIY belts.
  • Uses all DIY drive pulleys.
  • Uses all DIY couplers.
  • Full conveyor-belt y-axis.
  • One piece x-carriage design
  • One piece extruder design
  • One piece plotter design
  • Adjustable conveyor belt tension with bed height.
  • Conveyor-belt goes to both edges of the machine for end-to-end chaining of machines.
  • Hand-crank for conveyor belt.
  • A single block is capable of building all frame vertex points.
  • A single extended block is used for Nema17 motor mounts, 608 bearing axle supports and pillow-blocks.
  • The 5/16" holes fit both 8mm & 5/16" hardware.
  • Works with variable lengths. The design is not length specific, so you can build a range of machine sizes, from full size to compact with the same pieces.
  • The frame is chainable, you can build a linked multiple segment Longcat machine.
  • It uses only 1"x2" wood for all parts.
  • It uses a 35/77 system, where most of the parts are either 35mm or 77mm in length. The parts for the entire system can be cut to length in two fixture setup runs(with a few exceptions).
  • All cuts are 1-dimensional 90 degrees.

Scoop Extruder:

  • Adjustable tension with no pulleys or pusher blocks.
  • The "scoop" extruder uses the PTFE tube itself as the "idle pulley"
  • It uses the Makerbot Mk5 nozzle and hot-end tube.
  • Makergear style geared stepper.
  • Raysyu drive gear.
  • A Nophead style heater block.

Plotter Head:
This single pivot floating head plotter arm works consistently over a wide range of surfaces. The servo actuation provides fast on-off movements. The entire plotter arm and servo can be removed or switched with another pen without taking the pen out of position. The large 5/16" holding nut uses low force and acts as a knob that can be easily spun on/off by hand. The band clamp pen holder can hold just about any pen sized tool.


Continuous Raftless Multilayer Object Larger than Longest Bar of a Reprap:

This was originally posted Feb. 20, 2011. This is a multilayer beam 313mm long, printed on a Reprap 1X2 whose largest component is a threaded rod 306mm long.

This was printed with the 1X2 stepper driven conveyor-belt y-axis in a repeating pattern of 30mm bricks.

<videoflash type="youtube">pRLKnfQoPAU|320|240</videoflash>


Mrkim-continuous-02-19-11-4778.JPG
Mrkim-continuous-02-19-11-4777.JPG
Mrkim-continuous-02-19-11-4775.JPG

Continuous Raft:

<videoflash type="youtube">WSsPWOoyY2g|320|240</videoflash>

1X2 Vertex:

This part has generic support for modular triangulated structures. It solves the problem of building angular structures without having to drill accurate angled holes. It uses 5/16" rods of variable lengths.

This split vertex is easy to construct with only two straight holes and one straight cut in 1" x 2" wood. This single piece is repeated to form all the vertex points and fixed rail mounts in a frame structure. Since the part can be cut in a single jig setup, the entire frame set can be cut in a few minutes.

1X2-Drillpress-vertex-5-1024.jpg
1X2-Drillpress-vertex-3-1024.jpg
Mrkim-small-vertex-top-4692.JPG
1X2-35mm-vertex-v2.0.svg
Drillpress-z-axis-upper-clamp-1024.jpg

Motor Block:

This is the 77mm 1X2 vertex block that mounts Nema17 motors and 608 bearing pillow blocks. This block makes the motor block, pillow block, and shaft supports for the Reprap 1X2

This Motor Block uses no bolts to retain the 608 bearing and all the holes are shallow depths.

An aluminum shim is used when mounting the 608 bearing. This is a low force press-fit that is reversible. Aluminum Flashing with tin snips or Soda Cans which can be cut with sissors.

Cut shim to length 69mm (22mm * pi) x 19mm.

Mrkim-motor-block-4331.JPG
Mrkim-shaftsupport-4683.JPG
Mrkim-pillow-block-4633.JPG
Mrkim-motor-block-4685.JPG
1X2-77mm-vertex-block-v2.0.svg

Vinyl Drive Pulley:

It is made of two pieces of vinyl tubing.

Mrkim-vinyl-pulley-4798.JPG
Mrkim-vinyl-pulley-4793.JPG
Mrkim-diy-vinyl-pulley-4782.JPG
Mrkim-vinyl-pulley.JPG


Materials: 1/4" OD x 0.170" vinyl tubing 3/8" OD x 1/4" ID vinyl tubing

Assembly: Cut a section of each of the tubing sizes to a length slightly less than the motor shaft. For Example: The Kysan 1123029 motor with a shaft length of 24mm, cut 22mm sections of tubing.

First slip the smaller 1/4" tubing into the larger 3/8" tubing. Then press the compound tube onto the motor shaft. Done!

This part is also the Nema17-5/16" shaft-coupler.


Vinyl Pulley and flat tape belt in action: <videoflash type="youtube">XRgg57JnIOI|320|240</videoflash>

360 Bearing v2.0:

This is the linear bearing system used in the Reprap 1X2 z-axis.

This is a 360 degree constraining bearing assembly has adjustable tension. To fabricate, it only requires (3) holes in the same plane for both upper and lower bearing constraint. It also has a small amount of overhang.

How it works: As the "draw-down" bearing is tightened, it presses against a wider chord section of the round rail. This wedge effect tightens the rail against the opposing "capture bearings".

Because v2.0 uses larger 608 bearings and 5/16" bolts, a single draw-down bearing can be used for two sets of capture bearings, reducing the bearing count by one.

Design: 608 "skate" bearings are ubiquitous and can be found in local stores. There is also a printable 608 bearing that is theoretically interesting.

Mrkim-360-bearing-block-4912.JPG
Mrkim-360-bearing 4643.JPG

Scoop Extruder v2.0:

The Scoop Extruder has adjustable tension and uses no pulleys or pusher blocks. It is a single block made with straight cuts.

The "scoop" extruder uses the PTFE tube itself as the "idle pulley".
There is a scoop shaped cutout in the tube that allows the drive gear to move the filament.
It uses the Makerbot Mk5 nozzle and hot-end tube.
Makergear style geared stepper.
Raysyu drive gear.
A Nophead style heater block.

The two motor mount holes are slightly over-sized from M3 to M4 to allow for the travel.

Mrkim-scoop-extruder-4603.JPG
Mrkim-scoop-extruder-4490.JPG
Mrkim-scoop-extrurder-5264.JPG
Mrkim-x-carriage-4636.JPG
1X2-scoop-extruder-2.0.svg

Heater Block:

The Heaterblock pictured used a bicycle crank as source material.
It was cut with a hand hacksaw, and drilled in a drill press.
Aluminum foil was used to shim the heating resistor.

1X2-Heaterblock-v2.png

Thin-profile motor mount:

1X2-Y-motor-block-2.1-4918.JPG

The thin-profile y-motor-block uses (2) 11mm DIY M3 teflon standoffs

DIY M3 Teflon Stadoff Spacers:

Mrkim-diy-M3-spacer.JPG

Never run out of M3 spacers in the middle of the night.
Always have the spacer that is the exact right length. Why didn't I think of this before?

Materials: PTFE tube 1/4" OD, 1/8" ID (mcmaster 5033K31)

Cut to length with Utility knife. Done!

Plans:

1X2-35mm-vertex-v2.0.svg
1X2-77mm-vertex-block-v2.0.svg
1X2-608-shim.svg
1X2-x-carriage-v2.3.svg
1X2-scoop-extruder-2.0.svg
1X2-plotter-arm-v2.0.svg
1X2-plotter-riser.svg
1X2-77mm-zigzag-arm.svg
1X2-360-bearing-block-v2.0.svg
1X2-X-motor-block-v2.1.3.svg
1X2-X-pulley-block-v2.1.1.svg
1X2-belt-clamp.svg

Assembly:

There is an assembly instruction playlist for the 1X2 Compact on the home page in the 3D Printer section. [1]

Notes:

Misc: