3D print farm has grown by another new Delta

The new belt driven Delta is out performing all my expectations much quieter faster and smoother than the other machines, I will convert the small leadscrew delta to a belt driven one in the next few weeks. Will be assisting Christiaan and Magda with their Delta Build as well over the next few weeks, I have printed all their parts and they are just accumulating the last bits and pieces to complete their build.

3D Delta printer aliminum Reprap is running smoothly and is very fast

My new Delta runs very smoothly and very fast, all the motion is fluid and the print quality is as good as any of my other 3D printers I am very happy with the outcome, it is way better than I had anticipated I will now convert my lead screw Delta and build another for the print farm. My printing times and output can now double even triple.

Reprap Delta Nozzle assembly, extruder and heat bed completed, calibration done.

The last few days have been busy with lots of family events as the two oldest young woman in our house hold have had their Matric dances (Final year school functions) together with more outings. I have been busy printing parts for a friends build too. However I did manage to complete the last few fabrications for the new machine, the nozzle assembly extruder and heat bed are now all assembled and I have completed the calibration. This delta moves very quietly and smoothly and will be very fast, hope the extruder can keep up. Have a few wiring items to complete before some test printing which I am looking forward too.

 

Reprap effector arms completed ready to assemble and pic of 3D print farm busy at work

Just completed the effector arms aligned to the same length on the edge of my work top (perfect alignment tool) fitted the bowden tube fixer into the effector so all ready to assemble.

 

 

 



My 3D Print farm busy at work with the next Reprap parts

 

Most of my printing is with ABS as I generally make functional parts, ABS is far more durable, drills and taps well and has limited flex and memory.  PLA is far more brittle a little easier to print with and produces a great finish see print below.

 

Reprap parts and other prints last night

Last night I started printing the frame connector parts for another new Reprap Delta,  I also completed some parts for one of my flying Buddies (Instructors) one is making a radio comms connection for him to use while instructing flying students and the other asked for a new GoPro clip mount.

3D printer Delta build. All axis assembled and electronics connected and it lives.

The last few days I have managed to spare a few hours to get the assembly going, the frame assembled without a hitch and then I proceeded to assemble each of the axis, have hidden all the cabling neatly inside the extrusion. Then connected all the electronics with a quick calibration and upload of the firmware (same as that used on the small leadscrew machine).All the axis homed perfectly. I then sliced a fairly large print at 80mm a second and ran this from the SD card. WOW its quiet and so very smooth I am looking forward to getting this machine printing. Need to complete the effector, order some ball joints and make a new extruder.

3D printer Delta build starting to come together (big brother)

The build is slowly coming together, the frame is complete (uses 2 x 6 joiners) have completed the print of the 2nd set of Reprap parts for one of the three legs, the1st assembled within a short time and 3rd is on the printer as I write this. Some pictures to show the part set.

 All fitting parts are printed (true Reprap)

3D Print ABS acetone vapour bath to finish the final product.

The finishing  off of an ABS print with a quick acetone vapour bath produces an even glossy surface if more time was spent filing and smoothing the surface the more professional the outcome, be careful not to leave the print in the vapour too long.

Comparison of a raw ABS print and one finished with an acetone vapour bath. I used a thin walled glass jar (Old Coffee pot would be ideal) thinner the glass quick the vapour forms. placed it on the heat bed of the printer (100-110C) and then placed the print in the vapour bath on top of an old jam jar lid you will see the ABS gloss over within a few minutes, remove as soon as you are happy with the results, be careful not to leave it in too long as the acetone will continue to dissolve the print for a while after taking it out of the bath. This needs to be left for a few hours to dry properly before handling else you will spoil the glossy finish.

http://www.thingiverse.com/thing:149740

Print of GoPro clip mounting with small 3D Delta while busy with larger Delta parts

I am busy each evening printing all the rest of the motor and slider parts of the new large big brother Delta machine on both the Sumpod and the small Delta, pics and progress will follow, While waiting for a print to complete I designed a replacement GoPro clip mount in Sktechup and then quickly printed it with the small 3D Delta machine. The original part broke a few weeks ago so instead of ordering a new one I decided to make one my cost a few cents verse cost from the supplier for an original close to R200. ABS is also a perfect material as is less brittle and still retains good memory if the flex is not too great. The part worked out perfectly and clips without any chance of unclipping I will upload the design to Thingiverse and Sketckup 3D Warehouse. Skeinforge sliced it with no problem Slic3r struggled with this. http://www.thingiverse.com/thing:149740

Finishing with a short time in an acetone vapour bath to create a gloss professional finish

New Big Brother 3D Delta printer starting to come together extruded frame all printed joiners

The new Big Brother 3D Delta printer is starting to come together the extruded frame is all loosely assembles with printed joiners ABS, six sets of two identical pieces. As mentioned before both derivative designs are true RepRaps all plastic parts are printed by another 3D printer. I will update the pictures as this build evolves.

Notice the little sister (in the back ground) responsible for building some of this big brothers parts, true Reprap

 

Some other ABS thin walled prints that can be quite tricky

 

Bottle and lid

Thin walled test box I use, printing on the Delta little sister machine

 

Delta verses Conventional XY axis prints @ 0.125 mm and 0.25mm per layer

Here is a pic of the quality difference between My Delta and Sumpod. In all aspects size of the box wall thickness etc. the differences are in 10's of microns, the Delta makes the finished look a little like a basket weave I am not sure if this is due to the DELTA_SEGMENTS_PER_SECOND setting or the possibility of one of the arms being of a very slight difference in length. The quality though is still superb, these pictures are at 0.25 mm layer height. I will post some more prints at 0.125 mm layer height soon

Notice the basket weave effect on the left box this was printed on a Delta, the right a conventional XYZ Sumpod

Wall thickness of 0.32mm Nozzle 0.3 mm

 

As promised I have uploaded comparisons between 0.25 mm layer height and 0.125mm layer height on both the Delta and Sumpod see below

 



Reprap Wiki, Sketchup, Skeinforge, Slic3r, Marlin are but just a few that need to be thanked for amazing contributions to 3D printing & more

Just a few of the creators and groups that have made 3D printing available and inspirational for many DIY enthusiasts, these have been my leading sites and or organisations or individuals that have either knowingly or not made this journey possible for me. THANK YOU !! and to all of those that I have missed out too.

Firstly the Reprap Wiki pages were where I first learned that it would be possible for me to ultimately build my very own 3D printer. http://reprap.org/wiki/RepRap

After many many hours of research on all the available equipment at the time (no delta's then) I chose to invest in a Sumpod Aluminium courtesy of Richard Sum http://www.sumpod.com/   . Although I did have some small issues in the beginning Richard was always helpful when I called him up and I think he has learnt some valuable lessons while setting up and establishing his business too. The Sumpod is still in my mind one of the most accurate versatile 3D machines available. With the modifications I have done my Sumpod has done many 1000's of hours of uninterrupted printing almost 365 nights of each year I have owned it.

A large majority of our Arduino based 3D printers rely on the fantastic Marlin  Reprap firmware based on Sprinter and grbl. Copyright (C) 2011 Camiel Gubbels / Erik van der Zalm

Our designs have to come from somewhere and although there are many great CAD systems available Google SketchUP best suited me, was quick and easy to learn and perfect for my application and designs. http://www.sketchup.com/ 

Next the need to Slice the STL file into usable g-code got me using Skeinforge. Skeinforge is a tool chain composed of Python scripts that converts your 3D model into G-Code instructions for RepRap
Check out their wiki page and contributors, again a fantastic product to get me started, I still use Skeinforge and Slic3r depending on what I am slicing as I am still more familiar with Skeinforge.
http://fabmetheus.crsndoo.com/wiki/index.php/Skeinforge

The other app which I have only been using for a short while is Slic3r another STL Slicing program which appears to have even more functionality and is one of the Slicing choices from Repetier which brings your Printer, Slicer and G-Code together in one awesome package.  http://slic3r.org/


Repetier brings the elements of your printer size specific operational characteristics , your 3D design output the slicer and g-code output all into one package. I used to do each element manually but Repetier brings all these together in one simple application great product  http://www.repetier.com/

I have named just a few that have added value to my journey a big thank you to all. There are many hundreds of excellent resources available on the web and careful scanning of them almost always produces some or other little snippet of useful information about 3D printing.
 

Starting Out. My first of many 3D printers a true Reprap Delta

My 3D Printing Journey which has lead me to building a number of different 3D printing machines the latest a Reprap Delta design

Background.

3D printer South Africa a true Reprap Delta. 3D printer derivatives, have built own and operate a number of different ones. My father inspired my fascination on how things work, making and creating my very own ideas or derivatives of others good ideas and innovations, so when 3D printing came along I had to know more. After much research I finally settled on a Sumpod (www.sumpod.com) The main reason was that the machine  was universal  and capable of light milling as well as 3D printing even the possibility of fitting a small laser I thought. It had to be the perfect choice. Richard Sum has designed a fantastic product and I know I bought one of his first Sumpod Ali machines. When I received my Sumpod there had been some damage in transit and it was not functional due to several other factors too. It was 8 weeks of weekend time before I got my Sumpod to firstly do some light milling and then some printing. I rebuilt and realigned every aspect of the Sumpod and after 1000's of hours of printing it just continues to produce perfect reproduction after perfect reproduction I start most of my prints at night (bed time) and wake to find a perfect print awaiting me in the morning. . I have redesigned the extruder and nozzle but the rack and pinion X Y design is perfect for light milling. The quality of prints is also very good and the majority of my printing is with ABS and at .25mm layer height with a .3mm nozzle.

Light Milling with my Sumpod

 

Propeller from www.thingiverse.com blades .3mm thickness all ABS

Spool Holder for my Sumpod

This journey has allowed me to successfully build a few different 3D printers with my latest Delta producing some high quality prints, far better than I was expecting. I am busy with the second design of the Delta derivative so decided to share its evolution.

My first Delta This is a true Reprap machine all plastic parts were printed on my Sumpod