I have literally been working on the same basic design over the last three weeks

I too decided on aluminum for the gantry, as the price of 6mm/1/4" carbon fiber is insane. The weight difference isn't all that much, with aluminum (I spec'd 6061-T6) being only a little heavier. I wasn't too concerned over stiffness, as the linear rail would add the bulk of the stiffness, and with it extending almost to the bearings, the tiny unsupported area isn't going to flex much if at all.

 

The thing about using extrusion for the entirety of the frame is that you can fudge the shape square. With this style, you have to make sure your cuts are perfect. The other thing is the cost of aluminum. Extrusions is also a lot less $$$ and does not require much processing other than a saw. A 1/4" x 24" x 24" cast plate is in excess of $150 and still requires a water jet or mill. I'm not here to down talk the design at all, but one thing that played a huge role in the tool changer video (I'll have to find the link) is that he stated that the machine was designed and built based on an unlimited budget.

As an alternative to cast plate, what about 1/2" HDPE? Also you don't need 1/4" carbon. Even our high performance rc boats are crashing at over 80mph with 3-4mm carbon internal parts without an issue. I think my 4x300x400mm sheet was only $75.

It's a long video, but worth a look.

 

I was personally going to just use standard 6061 plate over cast tool plate. Drops the cost to a third of tool plate. The big detractor to using extrusion over a machined plate is tramming the linear rails. If the plate is machined with accuracy, the rails should be about perfect. Extrusion would take a lot more adjustment to get them parallel. And if you want to use M5 hardware, it forces you to use a larger rail and carriage, increasing the cost anyway.

 

It's nice and convenient when you can do the work yourself. I look forward too seeing this take form. Have you thought about electronics yet?

As for the extrusion...

• I don't believe E3D is using 2040. It looks much bigger, maybe 3060.
• 550mm is kind of an awkward length if you go by the Part Store sizes (250, 500, 1000, 1500). Is that something you factored in already? I know some retailers get up to 6m lengths of extrusion. I wonder what the Part Store gets...

 

Very interested by this build

 

I will keep an eye out for this build i am looking to do a very similar build

 

Really interested in this. I have a Delta and and corexy printer. I built the Delta after getting a small one to learn how it all works. Basically have done the same thing with a Corexy. Just got done reading the E3D blog on their tool changer and started pondering building my own to support the tool changer notion. Basically, as you said, it's not unlimited budget but want to get as much as I can stick into a decent design. I too have the tools to make my own metal parts so looking forward to how this progresses.

 

Nice work. I'll follow along.

I was inspired by the E3D design as well, though I'm not able to build a similar machine right now.
Where did you pickup your linear guides?

 

this is an interesting thread and I'm digging your approach. im headed down a similar path but will be opting for a triple z configuration using 1 motor. this should allow the motor to be mounted in the cool zone fairly easily.

similar to this but with mgn rails
Assembling the TripleZ (en)

 

I didn't explain my z motor thinking clearly in my previous post. My thoughts are to mount the Z-axis motor to the far right extrusion. passing the belt through a small slot in what will be the dividing wall between hot/cold zone. Can then connect that up to the triple Z system using a continuous 15mm PU belt. I'm shooting for a 500x500x700 build volume and will use 6mm 6061 for the sheet stock.

 

I'm sure you've seen this but for those following along at home:
Research and Development: Motion System and Tool-Changer | E3Donline | E3D Online

 

Nice work so far. Following along on this as well.

 

Any idea when you will release the drawing files for the plates and gantry?

 

can't wait !

 

Your design look great!

Any updates as to if/when you will release the CNC files for the plates? I don't have a CNC myself so I would have to have a local company do it for me.

 

can't wait to see the next update on this design.

 

I have the same idea of a build, but I am placing mgn and belt on top. Did you get it finished?

 

Hi, great job... did the fusion360 files ever get uploaded?

Any updates on the finished project.

Antony

 

I too am building a E3D inspired machine. Started late last year, still quite a bit to do...

 

That is pretty awsum... do you have a build site or forum post?

What size is your bed?

Would you share your design for the top plate?

 

No build site or forum post. The machine has been designed in 2D in LibreCAD. So just a dxf. Physical bed size is 300X300 but usable area more like 270 in Y axis with tool head clerances.