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Delta 3D Printer

A completely custom CNC machined 3D printer

The assembly was drawn in Solidworks. This design has a lot of odd angles, which required a significant amount of CNC mill and CNC lathe work to construct.

Special custom magnetic ball joints will be used for each of the required 12 universal joint connections.

Each spherical ball end was made on a HAAS CNC lathe to a 20 micron tolerance.

 

The two ball ends were then epoxied to carbon fibre rods on a special jig to ensure that the center-to-center distance is exactly the same for all six assemblies

Here is an action shot of one of the magnetic socket holders being machined on the HAAS CNC mill.

A rather difficult piece to machine, requiring 3 separate clampings.

 

These will hold the Delrin sockets and magnets which will attach to the linear rails and the belt drive system to form the actuator system.

Demonstration of the magnetic universal joint.

Each join can support about 9N of force. There are 6 joints in total supporting the moving platform

All custom CNC milled aluminum pieces after powder coating.

Beginning assembly of the actuator system

The RAMPS 1.4 Arduino controller, and all associated wiring:

- 5 stepper motors
- 3 limit switches
- 3 thermocouples
- 2 heaters

All of the wiring, hidden on the underside of the machine. Where possible, wiring was tucked inside the frame to maintain aesthetics.

Carriage assembly and flexure mounted limit switch. 

 

The vertical position of the limit switch is adjustable to allow for the home coordinate system to be adjusted parallel to the actuator coordinate frame

Dual extruders powered by stepper motors hooked up to planetary gearboxes.

The gearboxes were used since the motor driver was limited to 1A of current. By sacrificing some speed for torque, the extruders are much more effective.
 

There is a bearing follower which pressed the filament into the hobbed gear.

Entire assembly is custom designed and machined

Actively cooled heat sink allows for the filament to remain solid until it reaches the hot end, where upon a PID controller in conjunction with a 40W ceramic heater and thermocouple maintain the correct temperature.

The RAMPS Arduino controller seen below the belt drive.

The PID controlled heated bed is supported at 3 points by precision 100 TPI set screws.

 

This kinematic mount configuration allows planar adjustment of the heated bed. This is to allow the heated bed plane and the limit switch plane to remain exactly parallel.

The full view.

Printing a calibration 1" square to verify the dimensional accuracy and software setup of the non-linear motion controls.