Editors:

Marcin Jakubowski

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Graphic Design:

Jean-Baptiste Vervaeck

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Version:

Date:

D3D Universal 3D Printer Production Manual

v2.0 September 2020

Jan 1, 2020

Open Source Ecology Production Guide Series

Table of contents

Prelude: Notes on Using this Guide

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1. Introduction
1. Business Process Management Flowchart
2. Cheatsheet Printout - Cut, Pick, Test Procedure,
2. Bills of Materials
3. CAD
4. Tools
5. Cut List
6. Prep List
7. Controller Test
8. Packing and Shipping
9. Production Time Data
10. Completion Checklist
11. Troubleshooting and Repair

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Appendix: Production Facility

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Chapter 1

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Chapter 2

Chapter 3

Chapter 4

Chapter 5

Chapter 6

Chapter 7

Chapter 8

Chapter 9

Chapter 10

Chapter 11

Notes On Using this Guide

TED Talk Lin

ABOUT: This manual - the D3D Universal Production Guide - is part of a Production Series for the 50 Global Village Construction Set machines. The intended audience is producers. If you want to see how to build the D3D Universal from a kit - as opposed to preparing the kit as in this manual - then see the D3D Universal Build Guide.

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HOW TO USE: You can use a QR code reader to scan the bar codes to access content online.

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COLLABORATION: This is a collaborative effort in Distributive Enterprise. You are invited to help edit this guide. You can edit this document or make a copy, make your edits, and email us describing your proposed changes. To join our open source product development effort, join our Developer Team, or get hands-on experience in our Workshops. For other ways to get involved in OSE work, see the Getting Involved page on the OSE wiki. You can email us at info@opensourceecology.org

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1. Introduction

This guide is for people who would like to produce the D3D Universal in a distributed way with a flexible, open source microfactory.

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The D3D Universal is an industrial education and production 3D printer.

This manual focuses on distributed, collaborative, open source production. OSE trains and certifies producers to manufacture this machine either with Open Source Ecology, or independently.

OSE can provide certification on 3 levels:

• Producer certification, under the OSE Brand. Certification program coming soon.
• Producer training and certification, not under the OSE brand, but with the possibility of producing for OSE as an independent contractor
• Producer certification for people who want to produce D3D Universal independent of OSE. Certification program coming soon.

This guide provides build instructions for producing, quality controlling, and shipping kits.

If you’d like to get certified and produce these open source machines - we invite you to email us at info at opensourceecology dot org.

• Bill of Materials

Diagram

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Note: you can print out packing and production lists from here.

Includes bulk and unit sourcing

BOM Link

• CAD

Full files available in FreeCAD

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Part libraries are complete. Producers need how to work with these FeeCAD files to produce documentation, modifications, and other assets.

CAD Link

• Tools and Supplies

Tools used to build

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Tools and jigs for effective production are listed here.

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1. 5 mm hex key
2. Philips head #2 bit
3. 4 mm flathead screwdriver
4. Scissors
5. Razor or box cutter
6. Side cutters
7. Heat gun
8. Soldering iron
9. Wire strippers

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Supplies

• Thermal paste
• Solder
• Heat shrink

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5. Cut List for Kits

Cut

1. [1] mild steel plate, 1/16”x6”x6”
2. [4] 12" 8mm rod
3. [2] 14” 8 mm rod
4. [1] 6” 8mm rod
5. [2] 7.5” 8mm rod
6. [2] 5-¼” of ½” conduit
7. [2] 4-⅛” of ½” conduit.
8. Drill center of plate, ¼”
9. Drill interior of conduit
10. Weld on long-nut on the ⅛” plate
11. Grind edges of plate, rod, conduit
12. [1] Cut belt - 8’
13. [1] 6”x6” PEI
14. [1] 5.5”x5.5” carbon fiber blanket
15. [1] Double-sided adhesive
16. [4’] Split Wire Loom, ½”, fire resistant
17. [6’] D3D Universal Fiberglass Sleeve. Put tape around first
18. [8’] 32 ga kanthal wire (or 9’ 31 ga nichrome 60 wire).
1. Use 6” PEI as measuring stick: 16 wraps = 8’ long

Pick

• [1] ⅛”x6”x6” mild steel plate

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5.1 Wire Prep List

Overall

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Solder

• Tin:
• [3] Power cord ends
• [4] Ga 22 wires from plug into Power Supply
• Solder + heatshrink:
• [2] Blower extension
• [2] Fan extension
• [4] wires on 2 Endstops (solder + wrap)
• [3[ Z probe extension

Ferrule Crimps

1. [4] Ferrules on PS to RAMPS wire, 2 sides
2. [2] Blower extension ends - grey ferrule
3. [2] Fan ends - white ferrule

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Tools and Supplies

1. Thermal paste for heat break and under fan heat sink
2. Soldering Iron
3. Solder
4. Wire strippers
5. Heat shrink (for thermistor wires)
6. Side cutters (zip wire cut)
7. Scissors - cut off heat sock tip, belt

Materials

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1. [1] Power Cord -- cut off end
2. [1] sets of endstop wires - cut off black end and solder to Z probe
3. [2] Power from plug to power supply, 6” long
4. [2] Power from power supply to RAMPS - 10” long,
5. [4] Blower Extension from D9, Fan extension - 32” long.
6. Y endstop wire from RAMPS to endstop
7. X endstop wire from RAMPS to endstop

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5.1 Wire Prep List

Overall

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Fan

• Power from plug to power supply
• Power from power supply to RAMPS
• Power from RAMPS to fan
• Signal power to SSR signal
• 5V power to Arduino
• SSR signal wire from RAMPS to SSR
• Blower wire from D9 to blower
• X stepper wire from RAMPS to stepper motor
• Y stepper wire from RAMPS to stepper motor
• Z stepper wire from RAMPS to stepper motor
• LCD Screen wires from RAMPS to screen
• Extruder thermistor wire from RAMPS to thermistor
• Z probe wire from RAMPS to Z probe
• Y endstop wire from RAMPS to endstop
• X endstop wire from RAMPS to endstop
• Heatbed power wires from plug to SSR/Heatbed
• Heater wire from D10 on RAMPS to heater
• Bed thermistor wire from RAMPS to bed thermistor
• Extruder stepper wire from RAMPS to stepper motor

6. Part Prep Instructions

Modules

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• Base
• Bed
• Z axis
• X axis
• Controller
• Extruder
• Wiring

• There are 2 ways the machines are produced: as kits or as finished machines.
• Main difference is that the finished machine has additional quality control checkpoints, while the kit machine instructs the customer to perform the quality control.
• This manual shows the build of the Kit Machine

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Printed Parts

1. See D3D Universal 2 3D Printed Parts Spreadsheet

6. Production Instructions

Wiring

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• GFCI Module - 1:10 hr for 11 GFCI (6.4)
1. Cut-off power cord + open sleeve with x-acto knife
2. Find out which matches each prong on the plug by testing for continuity
3. Tin the cutoff end of the ground wire
4. Connect hot and neutral on the cable to hot and neutral on the GFCI outlet (it does not matter which is which). Connect the plug’s ground to the outlet’s ground.
• Plug Module - 1 hr for 12 plugs (5)
• Cut a 12” piece of 22 gauge CAT5 wire and pull the ripcord. Save the ground wire.
• Fold the resulting wires in half and cut the bundle into two 6” halves. Pull out two wires (any color) and strip each end. Keep the remaining wires organized in a box.
• Tin the two wires and then connect them to the plug (as shown).
• Power Supply Wire to RAMPS - 45 minutes for 12 wire pairs (3.8)
• Cut a 10” piece of 22 gauge CAT5 wire and pull the ripcord. Save the ground wire.
• Pull out two wires - a hot and a cold color. Strip the ends. Then attach a red ferrule on one end and a white ferrule on the other.
• Height Sensor - 45 minutes for 6 height sensors (7.5)
• Remove label attached to cord and unscrew the nuts
• Open an end-stop baggie, put away the end-stop and get the wires. Cut 4” from the end with the black connector. Strip the exposed wires.
• Cut three 1” piece of ⅛” of heat-shrink and slide them onto the stripped wires.
• Cut one piece of ¼” heat-shrink and slide it onto height sensor cable.
• Solder the wires together as shown here (slide 5). Slide the ⅛” heat-shrink over the wires and heat it. Slide the ¼” heat-shrink over the 3 wires and shrink it.
• Fan + Blower Wire Extension - 1:35 hr for 6 fans + 6 blowers (8+8)
• Cut off ends of fan and blower and strip the wires
• Cut a 32” piece of 22 gauge CAT5 wire and pull the ripcord. Pull out two wires - a hot and a cold color. Strip both ends.
• Cut two 1” piece of ⅛” of heat-shrink and slide them onto the stripped wires.
• Solder the wires together (hot to hot, cold to cold). Slide the ⅛” heat-shrink over the wires and heat it.
• Attach a white ferrule to each of the other ends of the fan wires. Do the same for the blower but using red ferrules.

6. Production Instructions

Wiring (cont)

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• Controller - 45 minutes for 6 controllers (7.5)
• Cut one leg of diode and lift up
• Install jumpers on locations shown.
• Install 4 stepper drivers in locations shown. Orientation matters. The dial faces away from the green power jack.
• Mount the shield on top of the arduino - with the shield's power jack on the same side as the arduino’s power jack. You may need to straighten some pins.
• End-Stops - 1:15 hr for 12 end-stops (6.3)
• Pull out two dupont wires - one in a hot color and one in a cold color - and cut them in half. Strip the ends.
• Remove the switch from the end-stop by cutting off the middle pin at the top and the two edge pins at the bottom.
• Cut two 1” pieces of ⅛” heat-shrink and slide them on the wire.
• Wrap and solder one wire to the left pin and the other wire to the right pin. Slide the heat shrink over the connection and shrink it. Slide a piece of ¼” heat shrink over the two wires and shrink it over the connection.
• Extruder Heat Sink - 2:53 for 21 heatsinks (8.2)
• Mark ½”x1” aluminum stock every 2”
• Cut the stock.
• Smooth edges with grinder. 0:45 for 22 pieces
• Mark holes with hole marking jig 0:55 for 22 pieces
• Transfer punch holes
• Drill out with 5.2 mm drill bit on drill pressusing diesel cutting fluid
• Tap the nozzle hole with 6 mm tap with heavy duty 300 RPM drill
• Spring Steel - 0:13 for 11 squares (1.2)
• Cut with abrasive metal cutoff saw at 6” 0:05 for 11 pieces
• Grind edges to get rid of burrs. Burrs are very sharp, careful.

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55.6 minutes total part prep

Not inc extruder + electronics test + pack

4 hour realistic assembly + QC labor

Extruder + elect test for workshops

Elect test only for workshops

$600 sales prince.

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6.3 Build Extruder

For the finished build version

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• Base
• Bed
• Z axis
• X axis
• Controller
• Extruder
• Wiring

• Take material from wiki. Full detail is at D3D Universal 2 Build Instructions

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Tools and Supplies

• Thermal paste for heat break and under fan heat sink
• 2.5 mm hex key
• 2 mm hex key for MK7 set screw and heater cartridge screws
• 1.5 mm hex key for thermistor set screw
• Soldering Iron
• Solder
• Wire strippers
• Heat shrink (for thermistor wires)
• 2 mm drill bit (cleaning out holes for threading
• 6 mm drill bit - cleaning out large idler hole
• Thermal paste
• Pliers - tighten heat break and nut
• Side cutters (zip ties, wire cut)
• 5 mm hex key - attach extruder to axes
• Scissors - cut off heat sock tip

Materials

• 30” of split wire loom
• [4] 32” extention for fan + blower
• [4] 3x8 mm bolt - motor attach + side piece of extruder
• [3] 3x18 mm - idler + blower
• [1] zip tie - entering split loom

6.3.1 Build Extruder Heat Sink

See Fabrication Drawings

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• Base
• Bed
• Z axis
• X axis
• Controller
• Extruder
• Wiring

11.5 mm from the Stepper side

Green is stepper motor side

11.5 mm

15 mm

Detailed Build:

1. Cut 2” length from 6061 stock
2. Mark 11.5 down and 15 right from corner for nozzle hole
3. Mark 4 down, 5 over, and 31 more for the fan screws
4. Predrill with 3 mm bit for guide hole
5. Drill with combo drill/tap on drill press
6. Drill other holes with 5 mm bit
7. Put this on the screw machine next time with auto lathe feed

5 mm

31 mm more

4 mm down

USE UPPER LEFT CORNER

Of block as reference point for measuring

Front holes:

Top threaded hole:

7. Electronics + Controller Test

Procedure - Upload all software. Then Wire:

• [4] Stepper Motors to RAMPS. Both sides.
• [3] endstops (one is Z probe). Both sides.
• [3] Blue Connections - Make heater, blower, and SSR signal connection to RAMPS. Both sides.
• [3] Power Plug: Connect 5V power feed, and 24V power feed + fan to RAMPS. Both sides.
• [2] thermistors (1 extruder, then bed)
• Connect LCD screen
• Connect power to power supply
• Connect power to GFCI
• Click reset on GFCI

Collect Materials

• RAMPS assembly + LCD
• [4] Stepper wires + Stepper motors
• [2] endstops + Z probe
• GFCI + Plug + 5V plug + USB cable plug in
• SSR + Power Supply
• Heater Block assembly + extra thermistor
• Fan + blower assemblies
• SSR signal + 5V signal + 24V power wires

1b. Kit Production Cheatsheet

Print out Cheatsheet for a step-by-step spreadsheet for shipping.

A spreadsheet with auto filled quantities for custom production runs is used here. Just type in the number of machines that you’d like to build.�

The procedure walks you through the cut list, pick list, controller test, and packing list - in the order these tasks should be performed to streamline the process.

Download Link

7. Test Control Panel

Attach all wiring

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• Base
• Bed
• Z axis
• X axis
• Controller
• Extruder
• Wiring

• Upload firmware using Arduino 1.6.8 with u8glib
• Attach Control Panel Components:
• Connect power to GFCI and plug in heat bed plug to power supply
• [4] stepper wires + motors
• [3] endstops (1 is Z probe)
• [3] extruder, blower, SSR
• [3] main power, fan, 5V power
• [2] thermistors
• LCD screen
• Click reset on the GFCI

Verify:

1. Observe that the fan turns on when power is plugged in
2. Check that hotend and bed temperature on LCD reflects the room temperature in C
3. Test 3 motors by going to Menu->Prepare->Home axes
1. The proper sequence is Z raise, X until endstop, Y until endstop, Z until endstop, and another Z with slower motion until endstop.
2. Note that not triggering enstops on X and Y causes a bypass, so you need to trigger within a few seconds.
4. Turn on extruder heater with Control->Extruder, and observe it getting hot to the touch immediately; turn it off as soon as you detect it getting hot
5. Turn on blower by printing any sample file, then going into Tune menu -> Print Cooling Fan -> 255
6. Test Extruder motor by disabling cold extrusion in Cura with M302
7. Set the voltage of steppers to 0.6-0.7

8.2 Packing

• Make USPS flat rate shipping large box
• Cut 24” from the top of a 40 gallon garbage bag prior to unfolding and place inside the box
• Start with heaviest stuff - Plates (1), Rods (2), and Motors (3).
• Leave rods bare - they take too much space otherwise
• Add Hardware double-bag in upper left corner to fill over the rods (4). Place the base in the box (5)

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See pictures folder.

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Plates

Plates

Rods

Steppers

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4

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6

7

5. Place the Power Bag over the Base (6). Add the Plastic Parts Bag (7), and Controller (8), Components (9), and Wires (10). Last, add the conduit pieces (11), under Plastic Parts Bag. Zip Tie entire bag to prevent spilling in case of accident. Fill rest of shipping box with paper filler.

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8.3 Packing - Bag Contents

• Plates
• Top/bottom metal of heatbed
• PEI with high-T tape. PEI has nichrome wrapped around it
• Carbon Fiber Blanket
• Rods - total of 9
• 6 plain, 3 painted
• Steppers - 4 for 3 axes + extruder
• Hardware Bag - see Kit Production Cheatsheet
• Just about everything!
• Controller Assembly
• After testing, parts are bagged up to 4 bags:
1. Power Bag + Controller + Wires + Components
• Green Plug and LCD unplugged so connectors don’t break
• Power Bag - large power components
• Power Supply + SSR
• GFCI + Plug up to lever nut
• USB power supply + cord
• Components:
• Fan, blower, and heater block
• Conduit:
• Placed in a separate bag, under Plastic Parts bag

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See pictures folder.

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Plates

Plates

Rods

Steppers

1-3

Power Bag

Wires

Controller

Steppers

Components

Wires

Components

Controller

Plates

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6

8

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8.4 Packing - Order - 11 Items Total

See pictures folder.

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*Conduit should go in step 1.

Steppes

1

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4

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Plates

Base

Conduit

Power

Bag

Hardware

Steppers

Rods

Components

Controller

Plastic Parts

Wires

Conduit

11

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11. Completion Checklist

From order to shipping

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• Send out Thank You and Shipping Address Form - 3D Printer Orders
• Work from a Cut and Prep List for preliminary and heavy fabrication
• Pull parts according to Picking List, which optimizes the sequence
• Produce Main Kit
• Wiring
• Extruder
• Controller Test
• Print Out Packing List - Pack according to Packing List
• Ship
• Get feedback on builds - Build Feedback Form
• Get feedback on usage after 1 year.