TOC
Print Bed Assembly
Bottom Frame
Vertical Frame
Bed Motor
Z Motor (2)
Extruder Slide
Controller
Wiring
Power
Supply
End Stops (3)
Spool Holder
Filament Spool
Vertical Rod Clamps (2)
Thermistors
(2)
Drive Belt
(2)
z
z
E
y
x
Modules (10)
Print Bed
Extruder Slide
Print Bed Motor
Z Motor Assembly (2)
End Stops (2)
Power Supply
Controller
Wiring Bundle
Frame
Extruder Assembly
Frame
y
E
x
z
y
x
E
z
z
z
z
E
Module Assembly Order
Wiring Bundle
Extruder Assembly
Controller
Power Supply
Print Bed
Print Bed
Motor
Threaded
Rods
Z Motors
Extruder Slide
Frame
55:00
End Stops
3:30
6:30
5:08
5:45
2:50
1:00
5:20
10:00
+9:30 belt
5:10
Extruder fan connected to power supply before power supply is mounted.
Learnings: Total time for assembly of built modules: 55 minutes. Extruder slide belt should be wound around drive and idler prior to mounting. Belt itself took 9:30 - as much as all electronics connections. Note Extruder Slide and Z Motors are put together as one, since Z Motors dictate Extruder Slide width.
z
y
x
E
z
1
2
3
4
5
7
6
8
9
10
Assembly and Disassembly Times
Wiring Bundle
Extruder Assembly
Controller
Power Supply
Print Bed
Print Bed Motor
Threaded
Rods
Z Motors
Extruder Slide
Frame
55
End Stops
3:30
6:30
5:08
5:45
2:50
1:00
5:20
10:00
+9:30 belt
5:10
:41
1:49
:48
2:30
:43
1:46
1:44
1:37
:35
9:45 to parts
:10
:45
23
z
y
x
E
z
Module 1: Frame
Frame
29
6 min base
23 min top!
To reduce build time, have second person work on Power Supply Mount to top frame - that eats up most of the time.
9:45
13 upc
Frame QC Checklist
1a
2
Bottom Frame: 2 L-brackets are inserted into each side
Top Frame: 2 L-brackets are inserted into left side
Side members are ABOVE, and NOT OUTSIDE of front member
Left bed bushing is 90 mm from left edge
Vertical frame is 90 mm from rear edge
4 corners are tightened on bottom frame
2 corners are tightened on top frame
2 bed bushings are tightened down
1b
1a
1a
3b
3a
1b
2
3a
3b
Module 2: Extruder Slide
22:20
Does not include: snapping bearings into right and left printed pieces, cutting or fastening of belt ends, and snapping in one of the 3 bearings in carriage.
9:10
Extruder Slide
Left Printed Piece
Right Printed Piece
Carriage
E
x
14upc
Extruder Slide QC Checklist
2 bearings are inserted in left hand printed piece
2 bearings are inserted in right hand printed piece
Pulley is inserted so that 3-4 mm of motor shaft are sticking out
Pulley teeth are facing towards the motor
Belt is wound around the pulley, with belt teeth facing the pulley
Flat side of right printed piece, flat side of left printed piece, and flat side of carriage are facing the same way
The double bearing of carriage is on the top side
Motor plug is facing up
Module 3: Z Motors
8:50
All done. 2:05 hr so far.
4:30
Z Motor Assembly (2)
Check orientation of motors
z
z
z
11upc
Z Motors QC Checklist
Motor plugs are facing up
Lock washers are under every screw
1 screw is in each elongated hole
Filament guide is attached
z
Module 4: Print Bed
27:30
Does not include cutting of belts or zip tying them, nor mounting of bearings on 3D printed parts.
Print Bed
18
12upc
Print Bed QC Checklist
Double bearing is mounted with rod inside of bearing for alignment
Rough side of heated surface is facing up
Screw head for bearing holders is on opposide side from bearing holders
Belt holder opening faces the bearing pair
Belt holder is in the hole pair farther away from the bearing pair
Thumb screw is under aluminum, with bolt head on top of the heated surface.
Spring is used between two plates om 4 corners
Belt is attached on one side
All 3d printed pieces are tightened down
Thumb screw is tightened so end of bolt is even w/ thumb screw
Tape up the wiring every 5” so it’s neat
Module 5: Print Bed Motor
3:45
All done.
2
Print Bed Motor
Make sure of orientation of motor. QC 1:
3upc
Bed Motor QC Checklist
Set screws tight
Screws are both is same slot
Teeth of pulley face motor
Shaft is flush with pulley
T nuts are mounted half way on the bolt
Connector faces away
Bracket slotted holes are to the right
T nuts are mounted on slot closest to you
Build Notes: __________________________________________________________________________________________________________________________________________________________________________________________
Module 6: End Stops
3:30
In all cases, printed part is standing up.
1: mid hole of endstop holder, plug facing up, bottom right hole of endstop
2: mid hole of endstop holder, plug facing down, mid hole of endstop
3. bottom hole of endstopholder, plug facing down, mid hole of endstop.
1
End Stops (2)
1
Total: 2 hrs 30 minutes for building all modules, not including prep.
5upc
Module 7: Extruder Assembly
16:20
5:30
Frame
Extruder Assembly
Includes:
5upc
Module 8: Power Supply
20:30
5:00
Power Supply
Make sure of + and -, and check plug polarity
5upc
Module 9: Controller
3
All done.
2
Controller
3upc
Module 10: Wiring Bundle
12:40
All done.
2:40
Wiring Bundle
Make sure all wires are labeled prior to winding
2upc
73 upc total
3D Printer Build Optimization
OSE Prusa i3 Build Based on a Modified Folgertech Prusa i3
Thesis Statement: (something proposed to be proven) - There is a cultural hunger for tangible productivity in a world where virtual reality is taking over many areas of life. Cultural transformation towards realizing one’s productive capacity can be accelerated significantly by rapid-learning, immersion build experiences. Such a model of production can be economically significant. To test this, we are proposing the Distributive Enterprise on the 3D printer as an initial example of cultural shift towards economically-significant mass creation of right livelihood activity, which has an immediate potential of rapid scaling. Such economic significance can be measured by observing the market spread of this distributive enterprise social production model.
Abstract: The goal for OSE’s 3D printer build is to enable a 6 hour build of 3D printer by using parallel, collaborative team work based on OSE’s Extreme Manufacturing. We are testing what it takes to reduce the build to a 4 hour optimized duration, up to the successful first print of a calibration cube, such that under a more relaxed setting, the build fits in a single day workshop. To do this, we are: (1) optimizing the Depth of Modularity for the parallel build, (2) preparing turnkey software for running the 3D Printer, (3) working as a mixture of swarm prep, pair build, and mutual assistance, (4) modifying build order to take advantage of a crowd build, (5) installing a rapid learning environment where accelerated learning is diffused through the build teams, and (6) and installing a self-actuating quality controlmechanism. The intended outcome of the first event is: (1) 24 people building 12 3D printers in a single day; (2) to demonstrate that the learning environment that is created can scale to as many 3D printers as allowed by space, under the guidance of a single event Master of Ceremonies; (3), that the productivity of such an event leads to a viable economic model of production; and (4), that this novel production model of open source Distributive Enterprise can be used to fund transformative projects.
Keywords: Extreme Manufacturing. Social Production. Open Source Ecology. Introducing advanced production to the masses. Economic Significance. Cultural Transformation. Economic innovation.
Strategy
General Strategy: Workshop leaders manage timing and QC. (1) Modules are have well-defined boundaries and scope, and firm build schedule exists; (2) Material inventory is done with Visual Inventory Cheatsheets; (3) pair up on Module Build; firm schedule and cutoff exists for each module, and one person in team finishes up as other person continues to next module; (4) work in pairs during Module Assembly. (5) diffuse learnings and work as a group to achieve fusion.
QC Strategy: QC occurs at build stations by: (1) prepared checklist rintouts; participants checking offworkshop leaders. Once all modules are built, they go to a quality control table, and are controlled as a group of 12 identical modules. Statistics are taken: number of errors per batch.
Definition of Success: EVERYONE finishes in time up to successful print of a calibration cube. This is a Team Effort. Fusion is defined as instructors not being a bottleneck - towards the point where the build runs itself by diffusion of learning.
Build Schedule Detail
Schedule:
Tools
Critical:
Overall Workshop List
Build Phases: Overview
Build Phases:
Then:
Troublespots
Calibration
?
Scope: Starting with built machine, what do the calibration steps take?
Glass Print Surface
?
Run ISO
?
Test Heat + Motion
?
Level the Bed
?
Print Calibration Cube
?
Install Firmware?
Run Software
?
Pre-Power Quality Control
?
Module Scope 1
Frame
Extruder Slide
Scope: Base and vertical frame, [4] Bed Clamps, Idler, 2 Vertical Rod Clamps, Power Supply Mount Brackets, Spool Holder Brackets, Everything tightened including rod holders to base and rods to rod holders. [2] right Bed Clamps are not inserted. Note: does not include Vertical Rods, nor Bed Rods.
Interface Design: Connection for Bed, Power Supply, Z Motors, Bed motor and belt, Extruder Slide, Spool.
Interface Robustness: Self-aligning frame. Extruder Slide adjusts in width to fit.
Scope: Carriage with 3 linear bearnings that rides on 2 smooth rods. Smooth rods are mounted on 3D printed end pieces, which have linear bearings that ride on the vertical smooth rods of the frame. Includes stepper motor and idler, and drive belt connected to the extruder carriage on ONE side. Includes vertical rods
Interface Design: 2 holes for vertical rods; 2 holes and nut catchers for threaded rod. 2 bolt connection to Extruder Assembly.
Interface Robustness: The module is largely self-aligning, and can fit onto vertical smooth rods because the length is extensible depending on how far the smooth rods of the Extruder Slide are pushed in.
Module Scope 2
Wiring Bundle
Extruder Assembly
Scope: [4] Motion Motor connectors, [3] Endstop wires.
Interface Design: 3 wire connectors; 4 wire connectors; hanging from power supply. 3 points of connection - motors, endstops, and controller.
Interface Robustness: Endstop end of endstop wires can be connected only one way. Rest have orientations that need to be considered.
Scope: Extruder + Fan; all wiring to Controller and Power Supply. Wire shroud.
Interface Design: [2] 3x40mm screws for mounting to carriage.
Controller Connection: 2 wire connector for thermistor; 4 wire connector for motor. Power Connection: 2 wire tinned for heater element; 2 wire tinned/hooked for fan.
Interface Robustness: Connection to motor can only be made one way. Polarity on thermistor and heater wires doesn’t matter; Fan power and motor connection to power supply and controller matters.
Module Scope 3
Controller
Power Supply
Scope: RAMPS board and Arduino connected to acrylic mount with 3 screws.
Interface Design: [2] screws to frame. [5] motor connections, [3] endstop connections, [2] thermistor connections; power plug from power supply; Power connection to heated bed and extruder heater.
Interface Robustness: Polarity has to be attended to in most places. Burnout is possible by mis-connecting endstops.
Scope: Power Supply, Power Cord, Controller Power Plug, 2 screws for frame brackets
Interface Design: [2] screws for frame. Wall plug. Power Plug to controller.
Interface Robustness: One-way plugs.
z
y
x
E
Module Scope 4
End Stops (2)
Print Bed Motor
Scope: Printed parts with circuit, and mounting screw.
Interface Design: Clamp-on with screw connection. One-way plug.
Interface Robustness: Robust with one-way plug. Mechanical connection needs adjustment.
Scope: Motor, mount, sprocket, and 2 mount screws
Interface Design: 2020 extrusion mounting; belt connection to bed. Located against rod.
Interface Robustness: 3 points of connection. Tensioning required.
y
Module Scope 5
Print Bed
Z Motors
Scope: Aluminum plate, heater surface, (4) adjustment screws thermistor, heater and thermistor wires, (3) bearings, and (2) rods
Interface Design: Connection to frame via rod clamps. Wire connection to controller.
Interface Robustness: Robust with one-way plug. Mechanical connection needs adjustment.
Scope: Motor, Angle Mount, plexiglas face, coupler
Interface Design: [2] screws to frame, adjustable up and down. One way plug to controller. [1] smooth rod goes into plexiglas face. Threaded rod goes inside coupler, tightened with 2 coupler screws..
Interface Robustness: 5 points of connection. Robust plug. Other connection points are located automatically via geometry.
Build Instructions 1: Frame
5
3
5
Build Instructions 2
Z Rods +
Build Instructions 3
Build Instructions 4
Frame QC
Key:
Distance
Parts
Tightening
Loose
1
2
2
3
4
5
1
2
10
5
Back of vertical is 90 mm from back of base
4
Make sure spool holder L Brackets are inserted
Tighten 4 corners, but leave vertical L Brackets loose until Vertical Frame is fastened. Verify it is perpendicular to
+- ¼”.
Distance from left bed bushing to left edge is 90 mm (front + back)
Frame
These 2 frame pieces are connected together. 2 Definition of done is when Z rod holder is in place, and everything is tightened down, ready for Z motors
3
Side member is the shorter member - and is above front frame member.
90 mm
90 mm
Wiring Bundle
1
2
10
4
Endstop side of endstop wire
3
Controller end of endstop wire
[3] endstops - 6”
[4] motor - 6”
[3] endstops - 12”
[2] motor X, Z - 12”
[2] motor Y, Z - 24”
Bundle
Motor end of wire
Controller end of motor wire
Extruder
2
3
10
5
Wire wrap the wire bundle
4
Tin 2 heater element wires
Solder fan wire extension, and use heat shrink
Connect 1 Motor Wire to motor, and label with 4 lines on far end
1
Tin and hook
fan wire
6
Tape wire bundle in 2 more places
Wiring
1
2
10
3
z
y
x
4
Bottom 2
5
Top 2: + and -
+
-
Motors
End Stops
Thermistors
Heat Bed
Extruder
position
position
3, 5, 6
1
2
z
z
y
x
E
3
5
6
End Stops (3)
10
½”
3-¾”
(from bottom of frame)
1-¼”
Print Bed
Size: 7-⅞”x8-½” glass
1
2
10
3
Print Bed
Controller
Print Bed
Size: 7-⅞”x8-½” glass
1
2
10
3
Print Bed
Credits
Ruler by Arthur Shlain from the Noun Project
Warning by Melissa Halterman from the Noun Project
Extruder Motor Mount Detail
x carriage
7 mm deep until shoulder of hole
stepper motor
Threads begin 25 mm into stepper motor
17 mm wide carriage piece
35 mm until threads
10 mm
25 mm
Bottom Frame
Vertical Frame
Notes
z