Workshop: DIY 3D printer WS2011

Project completed!

The team is preparing the project presentation for the afternoon. Small remaining tasks on the 3D printer are completed.

During the presentation, each team member presents his focus. The recognised problems are explained and corresponding solutions presented. The carefully updated mindmap represents the whole project and can be ported easily with all relevant data and the project results.

Conclusion:

The project aim was achieved. Thanks to the numerous, different tasks that had to be completed while constructing the 3D printer, the team gained insights into various disciplines.

The workshop was evaluated very positively from all sides. All students saw the participations as a personal success.

Hooray, it is done!!

Already in the morning, the first layers were printed. The results are not very beautiful, but we can now start with the phase of optimisation.

The first problem is that the height of the component does not fit. The printed models are too small. After an intense problem analysis, we learnt that the scale of the Z axis has to be modified in the firmware of the printer.

After adjusting various printing parameters, especially the speed in the X/Y-area and the speed of extrusion, the results were better. In the evening, the group discussed extensions to the printing hardware. We discussed a cleaning station for the extruder, an additional second extruder and a much larger version of the printer.

Since the project is coming to an end, the following day was discussed. It is time to document the work results.

The printer is printing

Honey, it is a log

:-( :-( Not printed :-( :-(

Although the tasks of the day were manageable and the printer should have printed in the afternoon, it didn’t work out. The adjusting of the platform, construction of a necessary endflag and a construction mistake of the hot end adaption of the extruder took a lot of time.

The highlight of the day was a short visit by another IDW team of the Faculty of Multimedia Production that made a short film about our workshop.

The delay in the projects progress shows how practice-oriented this workshop is. There are always problem phases in small and large projects.

In the end of a long day, we managed to solve almost all problems and were able to extrude the material PLA from the printer.

Problems

Problems

Yes!!

The week is starting with getting to know another Rapid Prototyping Technology, laser sintering and its specific work steps.

The work for the day is planned:

• fine adjusting of mechanical components.
• wise relocation of wiring.
• installation of the optimised extruder.
• adjusting the construction platform to the extruder.
• a housing for the electronic components.

The daily goal is the correct adjustment of all axes, endstops and the extruder.

We will print tomorrow . . . how exciting :-)

The team is tireless.

They decide: “The Z axes are flapping too much, that is not okay!”.

After a short brainstorming they decide: “the spindles of the Z axes must be turned and stored with bearings!”

According to the team slogan ‘Nothing is impossible’ the team members, who don’t have any experience with metal cutting, learn how to do so. 

In conclusion, we can say that the task was solved masterfully and the team members grew into it.

The project status was monitored by a brainstorming tool and the mindmap is updated regularly. To give access to all team members, we use cloud technology.

The day begins with a brainstorming, to make decisions about the projects state. We use a professional brainstorming tool. Our result is a mindmap, where each work step will be recorded.

The day is characterised by the transition to a project routine. All previously assembled components of axes and extruder are combined and adjusted. This work step is very time-consuming and reveals weaknesses in the construction.

It is very pleasing that step motors, electronical components, firmware and control software are working together without any problem. The technical upgrades are a total success (2 endstops/axes).

The printer is placed upon an adjustable foot. The team is not discouraged by conventional technology :-). Simple aluminium angles are cut, bored and function perfectly.

We are making progress!

The montage of the axes is nearly completed and we can install them tomorrow. Only the extruder is causing problems. The construction is again revealing weaknesses. They are so severe that we discuss a completely new construction.

The delivered hot end can’t be installed because the bore diameter seems to be too tight. Therefore, the group is making a digression into measurement technology, to carry out an incoming goods inspection.

Result: the component is drilled out.

The electronics team decides to extend the concept with 3 end stops (limit switches, that limit traverse), to limit the maximum of traverse. The ambitious plan requires a deep intervention in programming.

Shortly before the evening, the goal is completed. The minimum and maximum end stops are reacting. The extension of the concept is accomplished.

Hooray, the delivery is here! We are excited!
To pass the time in a useful way, the group is organising a short CAD instruction, to teach those participants that have less experience with 3D CAD about the working procedure with such systems. The STL data that we need for the 3D printer are created and edited with the help of a CAD system.

After the arrival of the last missing data, the work can begin.