II. Functional Knowledge

Frame

The frame holds the rest of the 3d printer components and thereby creates a space for 3d printing to occur.

The D3D frame consists of 6 square metal sides that form a cube. Compared to a rectangle, a cube provides more structural stability, resulting in more accurate prints.

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1. Introduction

Frame Module

III. Instructional

Cube Frame - Time Estimate: 45 minutes

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Use magnetic holders and JB Kwik Weld to glue the frame together.

Step 1: Arrangement for Build- arrange the plates as shown in photo to identify the location of the holes

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Step 1.1: Ask Instructor to Check your Frame Orientation�Ask instructor to check that your frame is oriented correctly. It’s important to be extra cautious that frame is oriented correctly because it’s permanent when you glue it together.

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Chapter 3

Parts

1) Left: should have holes for plexiglass (plexiglass holes closest to the center), plus YLeft axis. Holes should be on the corner for the plexiglass, closer to the “Middle”

2) Middle: 2 flat ones with no holes (for the top & bottom)

3) Back: holes in center along for ZBack axis, also, hole for cable chain must be on back left top.

4) Right: 2 holes for Y Right axis

5) Front: Two holes for Z Front axis.

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III. Instructional

Cube Frame

Step 2: Clean the Metal�Use degreaser, vinegar, or soap and a rag to wipe edges of metal

Sand the edges with rough sandpaper for better adhesion

The clean surface will adhere nicely together when you apply the JB Weld.

III. Instructional

Cube Frame

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Step 3: Set up your workspace �Put cardboard below the bottom face so that when you start gluing the frame together, you don’t glue the frame to your table.

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Step 3.1: Prepare magnetic holders�Magnetic holders consist of the 1” angles with 8 magnets placed on them:

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The magnetic holders can also be the magnets themselves without the angle iron. Magnets only work well.

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III. Instructional

Cube Frame

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Step 4: Place Magnetic Holders

First place 4 magnetic holders on the frame piece that is in the middle of your workspace. This frame piece is the bottom of the frame.

Place 1 magnetic holder along the outside edge of each side with the magnets facing outwards. Place each in the middle of the frame segment you are attaching them to, so there is about equal space remaining on either side.

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Magnetic holder in middle of side

III. Instructional

Cube Frame

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Step 4.1: Fold Up First Side

Fold up one frame piece so it is secured by the magnets, standing upright on the table.

The frame edges of the vertical side sit on the table rather than on the horizontal frame piece. The horizontal frame piece butts against the vertical piece.

III. Instructional

Cube Frame

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Step 4.2: Fold up Second Side��Fold up another side to form a corner of the frame.

The top edges should be corner-to-corner as shown. You should see a right angle forming between the ends of the two vertical sides.�

III. Instructional

Cube Frame

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Step 4.3: Secure the sides with a magnet holder��Place a magnet holder vertically between the two sides.�

III. Instructional

Cube Frame

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Step 4.4: Check Edges��Check the bottom edges as you go along and make sure they are flush against each other as shown. ��Anytime you need to adjust the frames so that they are more in line, go ahead and move them into the correct place.

Do this.

Avoid this.

III. Instructional

Cube Frame

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Step 4.5: Place the third side and secure with a magnet holder

Fold up a third side in the same way, checking alignment as you go.

Place a magnet holder vertically along the interior edge.

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Step 4.6: Place fourth side and secure with a magnet holder

Fold up the fourth side in the same way, checking alignment as you go.

Place a magnet holder vertically along the interior edge. At this point you should have 4 magnet holders along the bottom edges, and 4 vertically placed along the interior corners.

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Step 5: Frame Vertical Faces Quality Control

• Ensure that all four sides are corner to corner to the bottom frame
• Ensure that all four sides are corner to corner along the top edge where they meet
• Ensure that all four sides share the same length as the bottom frame such that there’s no width that’s longer than the bottom

III. Instructional

Cube Frame

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Step 4.7: Set magnet holders along top edges of cube

Set one magnet holder on each top edge of the cube with magnets facing up as shown.

Imagine the top frame resting on these magnets such that the top of the top frame is flush the the top edges of the vertical frames. In other words, the top of the cube will be one flat surface made of the top face of the frame and the depth of the 4 vertical frames.

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III. Instructional

Cube Frame

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Step 4.8: Lay Top Frame Down

You can now lay down the top frame piece on the magnets as if you were closing a hinged door.

The corners of the top piece sit in against the side pieces of the frame as shown.

It’s OK if there’s slight gaps between the metal frame. You can fill it in with JB Weld later.

Step 5: Full Frame Quality Control

• Top face is inset
• 4 top Corners are aligned
• 4 bottom corners are aligned

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III. Instructional

Cube Frame

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Step 5.1: Setup your JB Weld

• Squeeze 4 blobs each of part 1 and part 2 blobs of JB Weld Kwik Weld 2-part epoxy for the bottom and sides
• Squeeze out JB Weld of about 1-1.5 inches squared for each piece of the mix, but don’t mix them yet.
• Mixing the JB Weld together activates its welding capabilities. You have 5 minutes after mixing to brush it where it needs to go, then it will begin to stick.
• Do not touch, taste, or otherwise ingest the JB Weld. Apply it to the frame with gloves or an application stick.
• Get some toss-away cardboard
• Take a minute to plan where you will be spreading it. You will want to cover all visible edges and fill in any gaps between the frame pieces.

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Blob pair of

2 part epoxy

III. Instructional

Cube Frame

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Step 5.2: Prepare to Apply Jb Weld in between the appropriate faces of the frame.

• Mix the first portion of JB Weld until there’s no streaks, just grey
• You want to move fast as the JB Weld will start to set. Spend about 45 seconds per edge. Ideally, have a 2nd person help you apply JB Weld
• To paint the JB Weld effectively into the corners, you can get a small blob of mixed JB Weld and then slather it as close to the corner as you can get. Then you can use either your finger or a flat piece of cardboard to scrape the JB Weld artfully in between the frames

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Person should be wearing gloves.

Be sure to wear gloves. Epoxy can cause allergies over prolonged exposure.

III. Instructional

Cube Frame

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Step 5.3: Apply JB Weld Along Bottom on the inside of the frame�Place it between the corners of the bottom and the sides Fill into corners and sides such that there’s no gaps left

Our naughty model should be wearing gloves. Be sure to wear gloves.

III. Instructional

Cube Frame

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Step 5.4: Apply JB Weld Along Top on the outside of the frame

• Mix some more JB Weld
• Follow the same steps above to apply JB Weld to the edges of the top frame piece
• You do not need to put JB Weld along top on the inside of the frame
• This is because the JB Weld on the top of the frame will fill in any gaps and because it is significantly easier to put JB Weld around the outside compared with the inside for the top part of the frame.

Step 5.5: Apply JB Weld Along Sides

• Fill any gaps between the sides
• Mix together more JB Weld as needed, until you have applied it to all edges and filled in all gaps.

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Step 6: Wait for the JB Weld to Dry�For JB Qwik Weld, setting time is 5 minutes with full cure in 4 hours. Regular JB Weld takes 4 hours to set and 24 hours to cure.

V. Completion Checklist

Frame

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IV. Troubleshooting

Frame

How do you check that this component is successfully built?

Add high-level descriptions of what to check at the top here

• Check position of holes:
• Front and back have Z Axis Assembly mounting holes
• Left and Right have Y Axis Assembly mounting holes
• Left has controller mount
• Cable snake mount needs to be in back left side
• Visually inspect that nothing has shifted: edges are all tight against each other

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Misplaced Frames Sides�The holes are on the wrong spot of one of the frames.

If you mess it up, do not take the frame apart - just re-drill holes with a ¼” bit.

VI. Design Considerations

Module

The build rationale is that build doesn’t work well when using angle steel. It is easier to build from flat faces, which are self-aligning.As long as you work on a flat surface and the edges line up, then you’ll have a perfect shape, because the metal is CNC cut. You start with metal, no mysteries here.

Frame is made of mild steel. Steel typically has the highest performance-to-strength ratio of all metals.

You can nest the parts one inside another when CNC cutting. With CNC Cutting, cutting is affordable. [1] 4’x8’or 5’x10’ sheet gets you 3 sets of 4 or 5 nested frames�

Other Considerations

Advantages of Metal

• Can re-use 18mm screws through the frame
• Very stable: doesn’t burn, doesn’t mold (like wood)
• Low cost, high performance. But need to keep from rusting.

Advantages of Stone

• Hyper-precision and stable
• https://wiki.opensourceecology.org/wiki/Dan_Gelbart
• Buy a slab for $100?
• It’s common like limestone.
• Cuts straight. Easily polished.
• Too complicated and heavy for this application - but it is used for ultra-precise machines.