Building a Large Format 3D Printer - Part 5: Upgrades!
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- čas přidán 8. 06. 2024
- Part 5 of this massive printer build includes an enclosure, closed-loop motors, and electronics upgrades!
Files, Parts, and Info: www.drdflo.com/LF3DP.html
Large Format Printer Playlist: • Large Format 3D Printe...
D-Flo's Amazon Store: www.amazon.com/shop/dr.d-flo
📷 Follow Dr. D-Flo on the Gram: / dr.dflo
Part 5 is packed with serious upgrades and creative 3D prints. The build volume is enclosed with plasma cut sheet metal, CNC milled components, and topped with a massive ABS hat - 3D printed of course! Inevitably there were some issues and expensive mishaps as Dr. D-Flo attempted to print with ABS pellets, a material notorious for warping. But active chamber heating, a new pellet vibrator upgrade, closed-loop stepper motors, and CAN expansion boards vastly increased the reliability of this printer.
Table of Contents:
00:00 - Introduction
01:56 - Battery Backup
02:32 - Motor Brakes
04:02 - Motor Encoders
05:72 - Installing Motors
06:31 - CAN Expansion Boards
11:59 - Closed-Loop Tuning
14:11 - GD Print 1
15:45 - Vibrator
20:22 - GD Print 2
24:23 - Enclosure
30:58 - Hat
#massive #additivemanufacturing #3dprinting - Věda a technologie
Thank you everyone for your patience and support over the past 7 months. I wrote a blog post about my steps after graduating if you are curious about what I have been up to: www.drdflo.com/pages/Blog/Blog-post-23-1.html
I asked the injection molding press specialist at work about jamming, he says the easiest solution is to get "quenched" feed stock instead of cut pellets, they are like little bals or lentil shaped and they jam way less than cylinders. His second is solution would have been an agitator rod inside the hopper.
Our presses dont have any agitation in the feed hopper but we do have separate colorant hoppers that use a small (3/8" diameter) metering auger to control the flow.
@@paint4pain Excellent suggestions! When I am at bench with the vibrator, the pellets that I am using are underwater or quenched pelletized (round shape) and they still have a tendency to bridge. I believe this is a limitation of my small, by industrial standards, MDPH2 extruder. Its feed throat is too close to the diameter of the pellets. However, the abs pellets were strand cut (cylinders) and I had to have the vibrator running more often, so the geometry of the pellets definitely plays a role.
Try ASA. Same pros as ABS but less of the cons, especially the off-gassing.
Love your videos but I was just trying to set my (bell) notification and your Channel will not allow me because it's marked for kids??? I'm assuming you know this? I'm not sure if you have a setting on or CZcams just sets this for your channel automatically? I have probably 100+ subscriptions and yours seems to be the only one set like this. (we) I can't get any notifications if you post a new video..?
I think there is a strong market for any printer that can print body parts for classic cars. You need that rear panel? no problem here's one made of carbon fiber. You need a rare deck lid for a 69 Mangusta ? Here's a carbon fiber replacement.
happy this series hasnt ended
Heads up, when you crimp on your RJ-11(applies for RJ-45 as well) the cables jacket needs to be inside of the jack as well, such that when you crimp the connector, it actually pinches on to the cables jacket which then holds the wire in place, and acts as a strain relief. With how you currently crimped all of your RJ-11's there is no strain relief so if the cable gets snagged, it will damage your connections.
It won't fit. He's using cat5. In order to include the jacket in rj12 6p6c he would have to use silver satin
Edit spelling
You are so smrt.
@@bobbiac Really shouldn't have used RJ-11, RJ-45 is just plain better.
@@acorgiwithacrown467 The duet 3 expansions boards only have RJ12 6p6c connectors on them. If he attached 8p8c RJ45 connectors they wouldn't fit in the sockets he's trying to connect..
@@AJMansfield1 I meant the manufacturers, obviously he didn't have a choice...
Some large parts that are made on injection molding machines use a blend of PC & ABS together, around 5% Polycarbonate to 95% ABS. It gives the parts better dimensional stability. I wonder if that is something that would work help with your ABS issues. Awesome video though, keep up the good work.
This video beautifully showcased the difficulties in scaling up 3D printing technology. Extruding, bed heating and enclosure heating are so much more difficult at this size. Thanks for sharing real-world mistakes instead of hiding them and just showing successes. It made the video so much more enjoyable and relatable.
I agree with woodworker. Thanks for showing us both the upgrades and the pitfalls as it is encouraging to see your strategy for overcoming the obstacles. Great content here. I'd love to own one of these eventually but that price point eeesh. I'm sure it could pay for itself fairly quickly once the kinks are worked out.
By far the best series on youtube. Worth the 7 month wait.
just as a warning, benchys are extremely top-heavy, so if you try to float it it will instantly tip over. youll need to modify it if you want to make it rideable
Like increasing the fill % on the first layers?
Flat bottomed hull doesn't help either...
Just add weight in the bottom. Ill stop a benchie, add lead shot and resume print , then they float
Yeah, glad to see you back! 😊👍
Thanks! Glad to finally be back!
This is an amazing series and I'm learning a ton from this project. You do a great job with not only your project updates but also with your demonstrations. This project is a huge undertaking and I appreciate that you share the problems you encountered and walk us through how you solve them. Not enough people are willing to share failure! Some people assume things have to be perfect or else it wasn't worth it and that's simply not the case. This project and this entire video series is absolutely worth it.
Imaging having 100k and doing a project like that big respect
Congrats on the new job! You are an excellent teacher and brilliant engineer. I'm sure you'll do well in your new profession.
I loved watching pretty much every series you've ever done and have always learned something new. I especially love how you showcase the problems that you've encountered along the way. That's what real engineering is all about. Best of luck man.
About the vibrator you've placed on a timer, you could have a simple light/motion sensor to sense when the pellet flow stops, and then trigger the vibration. You would need a small reservoir of pellets so that when the flow stops there are still pellets available for the print head. BTW have you thought of hosting this printer on Twitch? Just a thought, but the metal bed on which the glass sits might benefit from a temperature probe, thermal insulation, or its own heater. this way you can prepare the glass for that first layer of the print.
Words cannot describe how excited I was when I saw you added a new part to this series. My favourite CZcams project, currently.
And congratulations on the teaching position!
Warping force is quiet something on such large printer. Fiber reinforced ABS is less prone to warping and it enables stiffer parts, probably a good option. PLA-ABS blend may be an alternative too, but lower temperature.
Found your channel at the right time
i love these long format videos.. really sucks it takes so long between videos. Keep up the great work. Congratulations on your new gig.
This guy print his own DESK!!!!!!!!!! Thank you so much to document and film your insane builds, it is full of critical informations and problems solving techniques, you are awsome!
You are really going for the gold with this printer. It's amazing to see such dedication and passion for a project. Keep it up!
Insanely impressive build, thanks for filming it all for us!
Congratulations on getting your dream job, Prof. D-Flo! Looking forward to the next status update on this project and anything else you have cooking up
This has been an exceptionally well made series. The complexity of the printer and the added work of filming and editing it all are really impressive. 👍🏻
I work in automation but I'm not an engineer. I've learnt a lot about the axis and motors I hear the engineers talking about. Thanks
You inspired me to build my own 900*900*900mm printer
Impressive how quickly you're dialing in on massive PLA parts. Amazing!
I am very impressed by the work you do on this project. Keep going please!
This is an amazing video. So much effort, and so thoroughly explained. I understood everything. I also learned so much. Just hearing u tackle minor printing problems, taught me 2 more troubleshoots I definitely needed to know. Good work, and thank you.
Congrats on the new job, im envious of your students. Ive learned alot from this build series alone
This is awesome for furniture and structural parts, also stuff like surfboards and boxes and what not, pretty cool.
Congrats man! You are such an inspiration and will be an AMAZING professor. Wow!
Stunning and awesome! Thanks for sharing your incredible work. Worth the wait. You do you it will be epic.
This build is epic, thanks for bringing us all along for the ride man.
Seeing you smile and laugh and “break character” so much in this video was awesome man. Keep it up!
Worst case, you have made a wonderful baby raptor enclosure for when dinos do come back..... :D
oh mate, delightful video! Wish you good luck conquering issues and improving your build! Thanks for uploads!
ASA warps less than ABS but still warps alot. I print in a heated chamber at 60c but the bigger you go, the more challenging it will be. Keep it up. Cheers.
Wow, this project has turned out so amazing, epic work!🔥
You put a lot of thought into everything, and present it very well. Great work.
Hey, id like to mention that a HEPA filter will *not* help much with the chemical fumes that ABS produces when heated. you need some sort of chemical filter, its best to have Activated Charcoal filters.
He said his filters are carbon filters…
i feel like little electric motor might be better than air fed fallet unjammer, if you have a power outage im guessing the compressor isnt ran by your battery system. this machine is an awesome feat of engineering! great work
Compressors usually have airtanks, so they effectively come with a built in UPS - I frequently just fill my airtank and then turn the compressor off as the tank holds enough pressure for the tool I'm using today. And with the pellet feed needing lots of air if memory serves he almost certainly has a larger air tank on his that will be able to keep that vibrator running for a good long time (if the electrical controls are actually functional).
I love your motivation in this project it is very inspiring! Thank you!
Your content is amazing. Super inspiring to watch you build this printer
The sound of those seven motors running drives my ears insane 😂
RIP that glass bed
The pallet of pellets behind you cracks me up. I see where my hobby obsession is headed :0
You are a total maniac D-flo. This is awesome can't wait to see the boat.
your content is just on another level
I love this project so much, great work and video
This is amazing!
all this time taking the vibes out and you add a impact hammer to the head basically super brave and interesting at same time but maybe counter intuitive but 100% interesting Cheers to that and your build
The printer is great and all but those white adidas 4D-s are looking amazing
Wow impressive built
awesome work man good luck with the new job
Man you do beautiful work.
This project is amazing. You are great.
I have some tips for you.
abs releases styrene during melting, it is not adsorbed on coal. the most affordable filter is fine iron shavings.
Glass for the table is usually used to make it smooth. But at such sizes, an ordinary thick sheet of iron with milling can be smoother and even work better .
Some plastics stick to iron without special formulations to increase adhesion. I hope you didn't manage to solve all the problems and my advice will be useful for you. Good luck with your cool project.
P.S. I am sorry about mistakes, my english is not good
Awesome. Awesome. Awesome. Entertaining and educational and envy inducing.
As someone who worked as an industrial mechanic in extrusion based industry for a decade, I can confidently tell you that the pneumatic vibrator, while functional, will wear out quickly. The cleanliness and dryness of the air you're feeding it will determine how quickly. Not only are they noisy, but compressed air is also expensive to continue making. The muffler will slowly clog with dust and gunk until it barely works, Requiring you to either remove or replace it. I suggest you switch to a solenoid based vibrator, or redesign the feed throat to include a small, motor-driven agitator.
you're a pioneer. thank you.
Glad to see a new video of you! Have been eagerly waiting for this one :)
super cool stuff and super high quality content, love it
That is a really complicated way to avoid the simple mechanical modification of counterweights for the gantry. Yay for the new job :)
You are awesome! Thank you for this content!
Hi, I have a lot of experience printing ABS.
You are going about the air filtration the wrong way. You should return the air to the printer. Ether move the entire fan / filter into the chamber or get an inline carbon filter that is has hose connection on both sides (for dirty and clean air) so you can pipe in the air back into the enclosure. That way you will not produce drafts from a big fans pulling out the dirty air and pulling cold air into the printer. Careful about acid washed carbon, as reintroducing the air that has been filtered with acid washed carbon will corrode your printer.
Also be careful with fan and filter sizing. That fans looks like its in the 700-900 m^3/h flow rate. I have something similar (for whole room filtration) but my filter is about 4x the size. I think it was something like 45 kg of carbon. The problem is that a given surface area of the filter can only support "some" amount of air flow. If you blow to much/fast the VOC particles don't get the time to be caught be the activated carbon.
Excellent. Thank you for this advice 👍👍
super impressive stuff! that printer is a beast
If the vibrations could mess up the print, I would place a slowly rotating twisted wire in the throat to keep the clogs from happening. Great build!
Love how happy you are with your final products
Awesome job as usual, and congrats on your professorship. Wondering if a big piece of ~1" Garolite with a segmented aluminum subframe would be preferable (albeit much more expensive)? Would recommend re-crimping your RJ-11 connectors -- the connector should be pinching on the outer sheathing of the cable to hold it in place so that you aren't relying on the tiny copper contacts for physical support (I usually leave about 5 to 8 mm of wire after the sheath, and you can usually message things into place).
Are you saying to use the garolite for the bed?
Garolite is a brand name for g10 which is commonly used in knife handles and is much cheaper
This is just non stop genious. I never 3d printed yet.
Love the video. Nice work!
Love the project. On my 3d printer, I was having issues with I consistent bed heat, so I used some adhesive foam to insulate the underside of the bed. This meant only one side was losing heat.
His "little hairs" on the model are the size of my filament ;D
You go Flo!
I’m studying engineering at Warwick uni and we have something just like this in our engineering build space!
Love the pneumatic agitator great idea.
Very nice, next time make sure the grey cable jacket goes into the RJ11 plug, so you know only clamp on the inside wires but the jacket as well.
Around the 24-minute mark I started giggling uncontrollably. Those "You wouldn't download a car" video clips *may* have underestimated me. :)
Again, amazing project. You're seriously taking on professional machines like the ones from MassiveIT for just 25k; In a professional environment, that'd be a steal. Als ocongrats on getting hired as a professor, that's super cool
always worth the wait!
Great projects cheerings from germany its really awesome !!!!!!!!
Love the video, can’t wait to see more projects on the milling machine though.
With ABS You really should be setting up a heat exchanger system. simple radiator setup on the out air, and pass with a simple pump to an other radiator setup on the IN air with maybe a heater. I would also suggest some Foam panel to the bottom of the build below the machine on the floor inside the footprint of the base. AS well it is also a good idea to have a good insulation blanket setup to the bottom of the the build plate. The last thing I would suggest is having 5 or more thermal sensors touching the build plate. And have that setup to the heating control unit or maybe a custom one. That way if the build plate cools too much in an area putting a lot of stress on the glass, it can be compensated for.
congrats on the dream job!
Hey just a thought, why not use a piezo sensor in the throat of the pellet receiver to detect falling pellets and if it doesn’t detect any pellets (I.e. it’s jammed) then use the vibrator. This would have a second advantage to pause the print of pellets weren’t flowing and can act as a “filament out” sensor?
i love your videos... and i really love how you show your problems and how you are working through them... there is only one thing that I hope you can improve... especially before you go be a professor at a university... and that is saying the word "exspecially" instead of "especially"!!!! :)
Something else that may help a lot is adding long low power squirl cage fans. like 2-4" diam. 3' long type. You can mount them on the 4 sides blowing down. This will make an air current blowing down hot air on all sides and welling up in the center. That should force a more even and constant temp inside.
3D printer ❤
Love this ✌️
Been waiting for this!
Good Information, thank you.
Right serious question here. Why didnt you just lay a blanket over the top of the printer to allow for the hot air to be trapped whilst printing the enclosure top.
i do really think that adding in the smaller failiars you have experienced more often would be helpful to teach the small things about engineering that a lot of people might not know, its all part of the prosses
Funny how now the icon of 3D printer calibration is seen as the end poduct 😂. Nice job, keep it going!
Great job on the video! Love seeing these projects. Keep up the amazing work. You should try some ASA if you can find the pellets. Way less noxious than abs.
You got hooked up good. I approve
You don't realize the true scale of that thing until you see two people trying to install the walls😳
One thing I was thinking while you were printing, was would the glass experience fracturing or some type of thermal stress. Turns out it would.
So why not go for a g10/FR4 sheet. Forgot what size your bed was, but they do make 4 ft × 8 ft sheets of varying thickness.
As for trying to keep the print more stable for more warp prone objects, why not add some type of heater element close to the nozzle that aims down at the print and gives it less chance of a thermal variance and lift off while the nozzle travels.
The forced hot air is great to keep the ambient temperature in the enclosure stable, but what about the ground, is there anything below to keep the ground from acting like a heat sink or sponge.
If not, could some type of thermal and fire resistant material assist in maintaining a stable environment for the print and bed?
Yes this is a great idea. If I break my second glass sheet I will go the g10/FR4 route. Honestly, I didn't know that 4x8ft sheets were readily available - similar price to glass as well. Thank you for your comments!
$25K ain't too bad! Of course that's the cost of the build without the mistakes.
I have those same couplers on my printer on the duel z there are awsome great choice
I like your solution to the bridging issue, but have you considered using a screw auger to feed pellets? It would vibrate much less!
I like this idea more than using the compressor vibrator! I was wondering if the vibrations like he’s using affects printing at this size.
Hello. I have to say, your project and work on it is amazing! I'm just a concrete expert, but 3d printing inspires me a lot but I still see some problems in your project. Your guide screw shows significant vibrations, its length is too long for such a small diameter. I'd rather use high helix pitch with multiple threads. For example Igus DST-LS-10×50-R might be a good choice. Of course, they also have a nut that is able to withstand higher temperatures.
Your upgrade to closed loop motors is great. Using the Duet 3 Expansion 1XD with CAN-FD connection not only does it allow you to connect closed loop motors, but it can also control these motors with a brake, which would be useful on the Z axis, where you would eliminate the risk of dropping individual corners. Best Regards. Antonin
thermal camera shots would so interesting to look at when its printing giant parts
This printer is getting bigger than my house.
You should create a machine to recover failed print material. You could find a way to grind up the material back into a pellet form. It would be worth looking into
I want one so bad but I can't believe they still cost the same price as my damn RV😂 Amazing progress as always and thank you for sharing it