ABCDEFGHIJKLMNOPQRSTUVWXYZ
1
REQUIREMENTDETAILS
2
Performance Specificationspower, size, weight, speed, torque, force, hydraulic flow, lift, precision, cost, expected lifetime, operating and maintenance costs, production/throughput rate, etc.
3
Size:24”x24” print area
4
Print Accuracy: +/- 0.2mm (good), +/- 0.1mm (ideal)
5
Power Use:Less than 1,500 Watts (limit for home outlets)
6
Bed Lift Capacity:Maximum mass (100% infill PETG (~1.3g/cm^3) cube at full 24”x24” build area) = ~285kg/627lb. Useful prints are likely to be less than half that. Minimum required 10% (arbitrary) of max mass.
7
Printable Filaments:Any commercially available filament up to and including the PAEK family (PEEK, PEKK, etc.)
8
Temperatures:500C Hotend, 300C Heated Bed, 300C Heated Chamberhttps://all3dp.com/1/peek-3d-printer/
9
Expected lifetime:Lifetime of user or longer
10
Operating costs:Electricity, filament feedstock
11
Maintenance costs:Periodic replacements of linear bearings, stepper motors, belts, nozzles, fans, halogen lights
12
Flow Rate:Supervolcano Hotend: 1mm Nozzle, 200C PLA = 87.50mm^3/s| That equates to 5.25 grams of PLA/min, 315 grams/hr, ~7.5kg/day. Reaches max bed lift capacity in 3.5 days (approx)https://e3d-online.zendesk.com/hc/en-us/articles/8960252072093-V6-Volcano-SuperVolcano-Maximum-flow-rates-
13
14
Module-Specific RequirementsDetermine how machine is broken into modules. Write down a list of modules and their explanations.
15
ModuleDescription
16
Universal Gearless ExtruderOSE's custom 3d printer extruder. Designed to use 3mm filament. Has the shortest distance from drive to hot zone available. 'Gearless' means not having a gearbox to maintain which leads to longer life and lower maintenance costs.https://wiki.opensourceecology.org/wiki/Universal_Gearless_Extruder
17
Fast Heated BedA halogen lightbulb powered heated bed (which runs on 120V AC and can kill you). Consists of a sandwich of steel plates, carbon fiber blanket, halogen lightbulbs, and metal piping/conduit for support. With PEI sheets installed, max temp is 178C. Without the PEI the limit is the 200C wire junctions.https://wiki.opensourceecology.org/wiki/Fast_Heated_Bed
18
Universal Axis (8mm)A belt driven CNC motion axis. The axis is comprised of a motor side where the stepper motor is attached, a carriage that moves along the 8mm (or 5/16") smooth rods, and an idler side that holds a belt pulley. https://wiki.opensourceecology.org/wiki/Universal_Axis
19
Universal ControllerThe Universal Controller is a platform consisting of a RAMPS control board, an LCD screen, a 24V power supply, a GFCI power outlet, and power handling solid state relays.https://wiki.opensourceecology.org/wiki/Heated_Bed_Chamber
20
Universal FrameA frame system that consists of 1.5" angle iron and 3D printed corners. The corners provide squareness to the frame and the steel provides sufficient mass to reduce vibration from the movement of the print head.https://wiki.opensourceecology.org/wiki/Universal_Frame
21
Heated ChamberAn insulated box that surrounds the heated bed. The heated chamber allows for the gradual cooling of the 3d printed parts. Gradual cooling reduces the internal strain caused by shrinking of the plastic which, without the heated chamber, leads to warping and delamination of the print.https://wiki.opensourceecology.org/wiki/Heated_Bed_Chamberhttps://wiki.opensourceecology.org/wiki/High_Temperature_Heated_Enclosure
22
CounterweightA mass and pully system that is used to remove the weight of the heated bed from the Z axis. This enables larger 3D prints on the bed.
23
24
Interface RequirementsInclude concept diagrams of geometry, any known technical design of geometry; qualitative features of interface
25
Interfacelist known design features of the interface between moduleslist know design features of interface to other machines in GVCS Product Ecology
26
Universal Axis Bolt PatternA grid of bolt holes that are on the carriage, motor, and idler sides of the universal axis. It is a 5 point pattern with 4 in a square with the 5th point at the center. Each side of the square is 30mm. Connects Universal Axes to the Universal Frame, other Universal Axes, and the Universal Gearless Extruder.
27
Universal Axis Magnet PatternSpaced to fit as many as possible on the piece. Sized to 6.6mm (6mm magnets +10%). The magnets allow for quick attaching, removing, and adjusting of the axes.Allows for attaching the Universal Axes to any magnetic surface. Can also be used to allow for quick tool changing of the Universal Gearless Extruder
28
Universal Controller WiringSee wiring diagram/video here: https://wiki.opensourceecology.org/wiki/Universal_ControllerConnects Universal Controller to any stepper motor (when an appropriate stepper motor driver is used).
29
Heated Chamber to Heated Bed RodsGasketing made from bags full of loose insulation. The rods slip between two bags.
30
Universal Axis (z) to Heated Bed RodsPlastic clips added to the carriage of the universal axis used to hold the rods in place.Used to hold 8mm (or 5/16") rod.
31
Universal Gearless Extruder to heated chamber cover
32
33
34
Design Choiceslist choices of components or design approaches selected from Tech Tree of Choices
35
XY Gantry LayoutThis is the fastest printing motion system possible with the universal axis. Separating the Z axes from X and Y allows the print to be any mass/size without getting dislodged by print bed motion. Additionally, the separated Z axes enable the heated chamber being operable at any temperature (No heat sensative components are in the heated chamber up to 300C+)
36
8 Z AxesThere are 8 Universal Axes on the Z direction to solve for the bed lift capacity problems in earlier versions of D3D Mega. See link: https://wiki.opensourceecology.org/wiki/D3D_Mega_v23.05_Conceptual_Design
37
38
39
40
41
42
Fabrication RequirementsAdmissible tools, materials, techniques used. Design for disassembly and repair: easy to service, access parts. No unreachable or untightenable fasteners. Transparent design that makes fabrication process as transparent as possible.
43
Admissible ToolsScrewdrivers, hex keys, hack saw, drill press, FFF 3D Printer, sewing awl(These are the tools I have access to)
44
Admissible MaterialsCut to size steel, 3d printed plastic (outside of heated chamber), open source electronics, cheap stepper motorsThe steel (angle iron, 5/16" rod, etc.) needs to be cut to size as I have no easy means to cut steel.
45
3D Printed PlasticThe 3D printed plastic components are essential as I have no access to a welder.
46
Open Source ElectronicsAllows for future toolchain degeneracy
47
Cheap stepper motorsLow cost while still maintaining good position accuracy.
48
49
Design for disassemblyThere are no permanent connections between modules or components. Everything can be removed and repurposed.
50
51
52
OSE Specifications
53
SpecificationDescriptionApplied to this project
54
Module-Based DesignMachine must be broken into modules and interfaces between these modules must be defined. When requesting design work, OSE requires a level of modularity that facilitates easy builds and reuse of modules in different products.See above module breakdown for details.
55
CompatibilityMust be compatible with these other machines, components, or systems: (list)Compatable with all current versions of the D3D 3D Printer family.
56
Product Ecology DesignDesigned as a Product Ecology - at the component, module, and machine level. This means any single machine is being designed with consideration of fitting in the overall set, not as a single machine. This means that the specific machine can be used with components from every other machine and that it can be scaled in a relatively unlimited way. The intent here is that we are testing the feasibility of the entire package being managed (capable of being built from scrap steel in 50 days with 4 skilled people and 12 apprentices and repaired/maintained as the entire set at no more than 400 hours per year).The D3D mega builds upon all of OSE's prior 3D printer work. Almost all components are interchangeable with the other sizes of printer.
57
Low cost.Common, off-shelf parts. Minimum machining. Capable of using low cost feedstocks.All components are readily available in either hardware stores or marketplaces like Amazon, Aliexpress, etc. The closest competitors of this printer start at $15000 retail vs the $1,500-$2,000 build cost of this printer.
58
Lifetime Design. Achieved by: bolt-together, Space Frame construction; modularity - allows new functions to come from machine, extending range of service; simplicity, transparency, and serviceability - user is in control and user can take responsibility for maintaining the machine in good shape; scalability - allows machine to grow/shrink with needs.All modules are designed for disassembly with common-off-the-shelf components. Any component can be readily replaced by the end user with minimal downtime.
59
Design for Scalability. Intensive and Extensive Scalability. Includes stackability via easy interface design. Machines should be designed to allow infinite scalability. Ex. Power cube can be built using the same structural frame in sizes from 5 hp to 200 hp, and these can be stacked in parallel or series.The printer can be scaled readily up to the maximum stock sizes available for steel plate and solid rod (usually 20') in all directions. It would be recommended to use larger rods (see 1" Universal Axis) and use the steel plate construction (instead of angle iron and corner connectors) for any printers larger than this size.https://wiki.opensourceecology.org/wiki/1%22_Universal_Axis
60
Modular Design.Involves clear interface design. Quick-coupled hydraulics and bolt-together space frames facilitate this. Modularity can occur on the component level as well, with the Stock Tubing and Stock Pivot Plates. Same PTO motor drives Open Source Car and agricultural implements.See Interface section above
61
Design for Fabrication. Design for minimal fabrication requirements. Design for common parts. Design for production of multiple, stock, identical components - like Legos and erector set.There is one machined part in the machine - the heat sink of the Universal Gearless Extruder - which can be manufactured using a cheap drill press, a hack saw, and a tap & die set. The remainder of the metal components can be ordered cut to size or cut from stock pieces.
62
Simplicity. Minimal parts count. Maximum redundancy of part types.This project uses the simplified (non-clamshell) Universal Axis components, and uses 4 pairs of identical axes together to operate the Z axis.
63
High Performance. Meeting or exceeding industry standards - as defined in GVCS Comparison to Industry Standards. Overbuild with Space Frames. Match production rates of industry standards.The ability to print PEEK and other engineering plastics in a build volume of 24" x 24" x 24" (~ 600mm x 600mm x 600mm) at the high flow rates of a supervolcano nozzle exceeds the industry standards of 3D printers at this price point.
64
Efficiency. OSE efficiency is measured on global performance (based on regenerative economic development as the goal) as opposed to point performanceTime is used efficiently by having a high flow rate for extrusion - allowing for faster prints. The Heated Chamber is insulated, which will reduce the energy needed to keep the bed and chamber at a consistent temperature. The machine accepts recycled filament just as easily as virgin filament.
65
Time of ProductionDesign for Fabrication should maximize module-based design to enable one day, rapid production in the Collaborative Production ModelDue to the module-based design, the entire project can be assembled by one individual over a weekend or by a small group within a day.
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100