Creating CAD that merges carriage clamp with end bolt with existing motor bracket into a single printable part (and bolt+wingnut).

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Looks like wingnut needs to be flipped up for clearance, but if it is on the end it will provide good clamping leverage and be out of the way. More visible and accessible on top anyway.

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I wonder if the bolt system could be 3d printed easily. I’ve seen it done. Maybe if it is bigger accuracy matters less, but friction of finer threads probably helps keep it static. The head would have to printed flat on the bed with the threads up.

Z axis actuating auto changer mount

Box structure with sprung pinned seesaw like latch (maybe two connected to form a parallelogram?) such that the latch(es) can latch partly like a mass balance. This may not work as well on the axis mount side so a different, but similar system may be needed that works in concert. Significant spring force may be required for holding heavy tool heads. This may require a lever design that multiplies force enough to counter a heavy spring. For milling CNC this won’t suffice. Precision metal sliding parts might be actuated similarly by axis motion probably along two axes.

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Considering center through hole in carriage for pin or complex shaped spiral/screw latch. Probably still need manual lever that slides to lock in another axis. Could try plastic leaf springs etc., but I doubt PLA is good for plastic springs. An internal Pushed plug on a spring might work for mounting, but adds parts and complexity. Maybe some partial gear teeth on moving parts could help if they effectively only allow motion under force or when some mount rods engage.

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Also considered large center tubes with flexible parts and catches, but it needs to mount on two sides for a tool changer concept.

RISC V

https://www.youtube.com/watch?v=yLs_NRwu1Y4 simple I32 implementation

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A point I got out of looking at the STEAM camp docs and thinking back on some of the candidate interviews is that while companies are somewhat competitive and wasteful much of the technology we have is so good because they are good at getting teams of people from different specialties to focus and collaborate well on the designing things. Online remote collaboration still seems to be a big hurdle. Often with the OSE teams the goal to get a lot of different things done results in team members being assigned separate machines. This isn’t inherently non-collaborative, but given time constraints and the online remote factors it can cause individuals to concentrate more exclusively on their assigned machine/part. This can reduce the hive mind/swarm effects gained from having the whole teams eyes on a single part or idea at once. There can be some waste because not everyone has input or the best input, but without the team view the positive effects are lost. Different approaches may be to prioritize the devices and then have the entire team work on aspects one at a time as quickly as possible. Or just treat the assignments as leadership roles and alot specific periods (week or two?) for the team to focus more on one. This could get most of the devices done quicker and to a higher quality. If a lower priority machine falls behind it could be prioritized in the next iteration.

Comments?:

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Battery Management Systems Research https://docs.google.com/presentation/d/1iUEES6Pqmc6Fz3nmrmUMhBxXQI_egm7yCMXfZ0wrr-0/edit#slide=id.g604660d2c1_0_13

Pros and Cons of Workflow where the swarm creates and edits a gdoc spreadsheet with sections for all parts and their dimensions to be listed. Inspired by https://wiki.opensourceecology.org/wiki/FreeCAD_Workflow

Pros

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• Emphasizes team preparation approach to using freecad before starting individual drawings.
• Enables & organizes swarm for efficient data gathering
• Listing all part specs reduces double work of looking up data on parts that interface with the part an individual is drawing.
• Data may be directly copied to FreeCAD Spreadsheets and aliased for dimensions
• Updates to dimensions can be changed in the gdoc then copied to freecad to update parts without significant editing of sketches & primitives etc.
• Reduces time communicating specs for interfacing parts thereby increasing discussion time for complex interactions between parts
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Cons

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• Creates another layer of documentation to manage and keep synced.
• Adds an extra step before starting CAD
• Likely large gdoc spreadsheets to navigate
• Adds more steps in FreeCAD that may be complex for new users to understand quickly
• Effectively using this in FreeCAD would mean all critical dimensions need to linked to alias’
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D3D Mini PVC Checklist

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1. BOM
1. Calc plastic mass for pricing estimates
2. triple check the bolt count
3. Check all parts and sizes
4. Update source links
5. ​
2. CAD
• Simple extruder assembly
• sizes and distances
• ideal position of extruder
• fix alignment of axis’
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3. Electronics and Wiring logistics
• Cable management
• Electronic enclosure options
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Possible redesigns of Simple Extruder

Smaller coil spring? Maybe a design for a leaf spring/thin metalwould work?

Can the base for the spring be moved to in between the bolt and the filament feed space of a shorter arm?

Making the filament feed system more compact will make more room for gears and extending the filament path up to the gears for flexible filament types.

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This looks like it may be harder to maintain ease of use. compressing the spring arm

For Flex Filaments main challenges are extending support up, but with a shorter path & higher temps from the heat block.

Poor representation for rubber mods

Simple extruder

• https://docs.google.com/presentation/d/1PRpAmQNzDs5laibZo86weuMaEYJLBIvFwt3KOx8DPn8/edit#slide=id.g5017be9ae8_0_53
• https://drive.google.com/drive/folders/1ikdLKij79Bbki5w1CprZXFbEXWGgmMFX
• It appears the CAD files may need more through review and possibly rework due to the following:
• CAD files look like they are models of preexisting parts
• There is inconsistency between FreeCAD files and some STL files
• Other than that the CAD looks good enough.
• To double check alignment of all parts a complete CAD assembly model will help.
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Stepper shaft looks shorter than most?

PTFE Tube in Al block?

Maybe I’m missing some things, but it looks like the stationary plastic part could be eliminated. A slight recess could be milled in the Al block for the spring bolt. It is an extra milling step and maybe this was done to deal with spring length?

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If the bolt and spring contacts the Al it would get warm, but also provide further surface area for cooling through the spring.

Questions are would the end of the spring get warm enough to soften the upper plastic part and can the Al block design be milled without compromising other features.

3D Printer firmware / Marlin Functions

Mains power blinked off this morning and internet went down reminding me the low power use of the printer for use with the UPS may be important. If software Pause/Resume from power loss works that would mitigate the issue and enable higher power printer hardware.

Simple extruder & mounting

Looking closer the angle bracket mounting the stepper appears to be metal not plastic. I think the new OSE horizontal X axis titan mounting part may work as well, but thickness mods may be needed.

This 2nd hole with set screw below must be the mentioned optional and unneeded heater cartidge hole, but I do not understand why it is on the extruder side of the heat break.

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It’s for 2nd hot end as a Multi-extruder?!

Thoughts on a more extruded frame (reprap style)

If the tubes were being extruded and holes could be printed for bolts that would eliminate/reduce the need to drill in pipe, which isn’t hard. Dropping the clamps at least for holding the major printer parts may make more sense in that case. Or if the clamps tend to slip need tape fasteners to stay etc.

Maybe printed nylon bolts have enough strength for some cases.

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Concrete in PVC

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• https://engineering.stackexchange.com/questions/2651/would-a-pe-pipe-filled-with-concrete-make-a-good-pillar
• https://permies.com/t/13991/PVC-filled-Cement-Hoophouse-Greenhouse
• https://www.deckmagazine.com/design-construction/railings/concrete-filled-pvc-posts_o
• https://www.sciencedirect.com/science/article/abs/pii/S0950061817317658
• https://hackaday.com/2013/10/17/unorthodox-home-made-cnc-machine/#comment-1646837 Commenter sucessfully used foam spray and slow set epoxy with sand for infill in PVC as stiffener.
• There are 2 part foaming epoxies. They even pour them in place of concrete in the desert (no water) for large power poles.
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• https://reprap.org/forum/read.php?1,578597,page=2 Good thread with discussion of PVC pipe, printable tube structures,
• Vibration analysis of a printer with a phone and some solutions https://youtu.be/Ws1JfHl3Y0o
• Could an entire frame be assembled and tensioned with wire or extruded filament?
• It might be tunable from the exterior
• The printed corners of the PVC Mini could have holes added back for running wire through.
• Extensive experimentation could be done of patterns for compressing/tensioning different parts of the frame together.
• Cementitious material could still be added to parts of the frame to add mass and balance.
• Wire could still be run through it, but that might make assembly parts more permanent.
• Parts could be added to alter this, but it would increase complexity.
• Wire/Filament seems simple and accessible

Wire/Filament Compression of Tubing

Z/Bed drop with belts

Is a worm gear needed or can it be solved entirely with software pause/resume and probably high end drivers. Closed loop steppers would likely be overkill in all, but the highest end systems.

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https://hackaday.io/project/108264/gallery#208aac2ca1f5aeac25f04c8d7914bedf

Open Source Standards for rating Printers

While there are benchy’s and printing is complex it would be useful to define clearer Open Standards for what printers can do.

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I’m currently unfamiliar with any current standards in the 3D printing industry.

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Standards could clarify abilities for industrial use better. Instead of benchy’s particularly difficult parts could be demonstrated to be printed reliably at some max speed.

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Perhaps living hinges or better yet functional pin hinges and other useful industrial features.

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This would also set clearer objectives of quality and goals for OSE D3D & other CNC machines.

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List of useful, but perhaps difficult to print at speed parts

• Hinges
• Curves/Angles?
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Abe OSE Working Doc

X parallel alignment parts explanation https://youtu.be/q9xx1iliP1U?t=709

D3D PVC Mini Assembly and potential alignment with underslung X -axis extruder.

Angle bracket width is 1.15”

Bed Rod lines up just below clamp. See slide above for distance between carriage and nozzle on ? extruder.

• Can metal pipes be polished and accurate enough to be considered for replacing rods in certain sizes of printers?
• Can added tension/compression etc. increase stability and maintain straightness?
• Can a reasonably simple CNC pipe polisher be developed and if needed?
• See photos of written material
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Physics and Formulas for various potential methods of compressing/tensioning conduit need to be explored.

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What are ratios of force for length?

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What methods could be developed? Such as heavy tensile fencing wire with washers small nuts forced on? Or other locking mechanisms? Preferably off the shelf parts.

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Back end frame around PC’s needs to be wider. More room could be made if CNC cut plate can be used. Likely requires more complex shape than these simple diagrams for strength.

The front arm portion looks like it needs some tweaks still. Maybe more CNC cut parts of the front.

Boxed? side plates with cross shelves for power cubes. Weld pivot point suppports for pipe bearings onto outside around arm.

Moving the pivot point is another possibile solution, but that is optimal for the reach height. Moving it higher makes the arms longer and moving it forward reduces the distance to the cylinder pivot point.

Moving the rear cross beam of the LT back 4” should give enough room to mount the auxiliary PC’s on one layer.

Breaking down the LT into modules for smaller faster files I also noticed the square tubing really needs to be replaced with realistic tubing so part interfaces and welds are more clear. It is also needed to do FEM for checking strength of custom parts for fail points.