It is running!

First print video:
https://goo.gl/photos/iLR45rEwGqzyDJTW7
and
https://goo.gl/photos/3y88xqDRfuDeizWD7

This test print is PLA at 60mm/s and I do not yet have the PLA cooling fan ducts designed/installed - working on that now - however the print result is as it should be considering no cooling.

I went to my machine shop this morning and prepared a hexagon shaped 0.250 inch thick piece of MIC6 aluminum plate to be the base of the build platform. Checked it on my large granite slab and was pleased to find it was more than flat enough to suit me. Applied my Keenovo 120 volt, 900 watt heater to the underside and mounted it to the frame.

 

Now I have it printing its own cooling fan ducts from PETG: https://goo.gl/photos/h9ucwdBeNenakcio8

 

That's awesome, Jerry! Nice work! Making me wish I could get mine going already... a few more parts are showing up this week, but its going slower than I was hoping. Sigh.

 

Progress report: it is now running a 20 hour production print job! Calibration cubes and other small test prints have been as close to perfect as I could have hoped for.

https://goo.gl/photos/HxAKCpTY2umhd6t67

I hope to gather and post all my STL files for my parts soon - apologies to those who may be waiting for them!

 

Thank you very much Kyo. Will let you know how they fit.

Regards
Stefan

 

Hello, Jerry! You should be very proud of your work on this project. Not sure I agree with your color choices on filaments, but I'm sure you have a reason. My results have been less than optimal; I suspect that several iterations of carriage "re-dos" may be the problem, with loss of attention to squareness, etc. However, my printer prints, which is good.

My controller is an Azteeg x5 mini, v2, running smoothie ware. My slicer is S3d. Marrying the two has been a challenge but I suspect the problem is me.

Keep up your great work!

 

Long overdue update... I got busy with other work and now have several massive 3D printing jobs to do - over 20,ooo parts to be printed in addition to various regular production parts I make at around 500 per month. I'm in the process of building 10 more of these at a slightly smaller 400mm rod length. I'm also designing a larger cartesian printer at around 14 x 14 x 14 inches with mostly metal parts - and will build 4 of them

Lofton, Thanks. My color choices are mostly the by-product of what is on hand and what's in stock at Amazon among my favorite filaments (Hatchbox and Esun PETG, Esun PLA+ (Pro), Verbatim PLA).

My experience thus far with the Duet 0.8.5 boards and the DC42 firmware and the DC42 IR probe has been nothing short of perfect. They're working on a new Duet board as well that I'm very eager to get my hands on when released. I even purchased the Kossel Mini kit shown in the photo below because it already had those items included and I needed another small printer up and running quickly.

My STL files are here: Dropbox - Latest STL files

STL zip file is also attached to this posting.

I also changed my carriage design. I wanted to eliminate the eccentric adjusters and have only 3 wheels with easy tension adjustment - similar to the Kossel carriages - and have it sized appropriately for the 20x40 v-slot to give good stability. I designed it such that the tensioning screw also acts as additional bracing to reduce the tendency of the wheels to splay outward when tension is applied.

The mess in my office:


The new carriage:

 

That's awesome, Jerry. Thanks for posting all the STLs.

ALL: Is there anyone here who would be willing and able to print me a set of Jerry's parts? I've been trying to work through my maker space, but their printer has calibration issues that have resulted in a number of failed prints that no one seems to know how to resolve. I'm happy to pay for materials and shipping!

 

My new extruder - a modified version of this which I'm running with great success on this big delta printer: B'Struder: Universal Bowden 1.75mm Extruder by tempo502

I still wanted something with more control over the idler bearing tension - so I modified his design to my liking. I also added the mount I needed to mount it on the outside of my 20x40 tower and have it oriented well for the bowden tube to curve around to the hot end.

Added to my files collection here: Dropbox - Latest STL files

 

My new carriage design changed the offset of the belt relative to the tower, so I needed to revise the belt idler roller bracket such that the belt lines up with the idler. I was not able to stay with the same design as before. This new one simply sits in the top of the vertex and is held in place by belt tension. Not as clean as I wanted it to be - but it will work fine - and was much faster than redesigning the vertex specifically for holding the idler and then printing a pile of them. Uses the same idler bearings and printed roller as before, held in place with M5 bolt and nut (just tight enough to keep the bolt from falling out but not tight enough to squeeze the bracket against the roller!)

STL file added to the set here: Dropbox - Latest STL files

 

I got a E3D v6 hot end and the groove mount jerry supplied us didn't fit so I created a E3D v6 groove mount based off of jerry's. See attached.



I wanted to thank jerry for all his work on all this. This is the first build I've done and things are going quite smoothly!

 

I suspect you noticed the E3D groove does not want to snap into final position as if my design isn't quite wide enough? I designed it to be very (VERY!) tight and I use this tool to make it go:

Thanks for your thanks. I have 13 of these (in 3 different sizes - 400mm, 320mm, and 240mm) completed at the moment and all are working flawlessly thus far. I have some of them running 24/7 for many weeks at this point. I'll have 20+ of them running soon just to keep up with what I've stumbled into

 

Now is also a good time to mention....

I revised my extruder mounting to have the bowden tube at an angle I like better and to make it a little shorter. Also added a little bracket for the wiring under the extruder bracket.

These updated STL files are all in with the others at Latest STL files

 

Ah, I just took a look at the measurement drawings to compare the E3D V5 and V6 and they are in fact the same diameter. Your hot ends must be permanently in those groove mounts!

Oh well... with the one I made it's possible to snap the hot ends in with my hands. We'll see if it stays well enough in place.

 

I think they're almost permanently in the mounts - it would take considerable effort to remove them. I didn't want any chance of the hot end working itself loose so I may have overdone it with the tight fit. Your design may prove to be more than good enough.

 

well I couldn't resist any longer --- started printing parts on my what started as K8200-Drag but has changed over the year reprinted everything --- now I've found Delta-Six --- here I go again.
most impressed with jerry426.
cheers
malc

 

Loving your mods Jerry426. I am going to adopt a fair bit of your stuff. I am going to go and try to rebuild it in fusion 360.. I'll try to show some progress along the way.

 

jerry, would I be out of line asking for your firmware settings? I have started tinkering with the marlin firmware and I'm having some issues getting the movement of the head across the bed straight.

My build is for a 400mm build plate so the base of the printer uses 500mm beams and 1000mm vertical beams. The rods are 400mm as well. I'm pretty new to configuring the firmware so it would be nice to take a look at something that would be close to my specs, if possible.

 

I think jerry uses a duet control so probably not marlin. I got a rumba control and use marlin on my k8200-drag but not yet on delta.
have you done a compare with mini Kossel against generic in marlin might give you an idea where to go next.

 

Hello,
I have started to build one beauty like this, but i have an issue with the carriage.
My wheels are different, and are not fitting on the carriage.
I'm not so good to drawing, anyone is using this type of wheels and is kind to share the carriage stl?
Br

 

I'm not sure but I think that carriage design is for a 2020, not a 2040. Or you didn't get the mini wheels.

 

Yes,my wheels are bigger, and the alu profile is t-slot 20x40, and the carriage it's ok for mini wheels.
This parts are all that i have found to buy quick here on town.
I have to make those two to work somehow, wheels on profiles.

 

You will have to remake the carriage to accommodate the larger wheels. Is this the carriage that was included with the Delta6 files? It doesn't look familiar.

 

The carriage and all the STL are from Delta 6.
I have found i little error on the file of the black piece on my photo.
With the red i have markd the larger hole, shod be on the right side of the piece to be able the screw to slide when install on aluminium profile and fit tight the wheels. ( sry for my english)

 

I'll have to go back and look at those files later. Those weren't the ones available when I started mine. If they are done in OpenSCAD like the original files, it should be fairly simple to modify them.

 

Just mention, to spare maybe some time and Q/A for the next builders.
I will try to make the carriage for my wheels and that part also.

 

Dan,

I designed that carriage to work with the 2040 and delrin mini wheels as shown in all my photos. If you get the mini wheels the carriage should work perfectly. I have many of these printers running now using the design. Also not sure what you were trying to point out with your black piece, but it also fits that carriage without modifications.

All of my parts are drawn in SolidWorks.

I will try to help you further if I can.

Jerry

 

I just have finish the frame, for now i'm using only one row for the horizontal part. The electronic part will be arduinio with ramps.

Jerry, great job!
Maybe i will be lucky and find the carriage for my wheels on the net, i didn't find any provider in the area for the delrin mini wheels. For now.