• Overview

    3D printing can afford relatively fast iterations in the manufacture and design of a physical product. The goal of this project is to research, source and build a 3D printer that can print in a high enough quality to allow for reasonable discussion and exploration, providing a cost effective, lower fidelity thinking step before moving to more expensive, higher quality steps such as laser sintering, stereolithography or casting.

    A Fused Filament Fabrication type designs offer the most practical choice for an affordable 3D printer right now.

  • #Printer Types

    Laser Sintering

    Laser sintering uses a high powered laser to fuse a product’s layers from a bed of powdered material.

    Example on YouTube

    Patents currently keep laser related 3D printing out of reach of the hobbyist. These patents expire in 2014.

    Fused Filament Fabrication
    (same as Fused Deposition Method but not trademarked)
    Wikipedia
    An additive method of 3D printing where material is put down in layers. A heated nozzle melts thermoplastic material and puts down the beads of material in layers, which cool and harden immediately.

  • Design Considerations

    Print resolution

    A reasonable target quality for this project is 100 microns, or 0.1 mm. This is on par for many popular 3D printers available for purchase today.

    Build and Maintenance Cost

    Cost is another consideration. Cheap is good, as long as the build quality does not suffer. Ordering parts overseas (China) is not a time issue as shipping can take as little as 1 week, and can be a minimal cost. Overseas parts can often be subject to less distribution in NA, sometimes resulting in fewer public reviews of sourced parts.

    Printable Material

    ABS and PLA plastics are common choices for print material. A hot print bed increases build cost but can prevent warping that sometimes happens when printing larger parts.

    Rigidity

    Rigidity is a major factor in achieving quality prints at a higher speed. The inertia of the moving metal print head can cause the printer frame to shift while printing, causing inaccuracies in subsequent layers.

    Tuning

    A printer must have accurately repeatable, perfectly straight axis movement to ensure print layers are aligned. The printer frame design can accommodate adjustments.

  • #Printer Location
    Where are we going to store and operate this thing?? 3D printing can be noisy. None of the designs we are considering include a housing design to reduce printing noise.

    Can we get someone to sponsor a location? Can we buy a cube van to 3D print Breaking Bad style?

  • #Models

    These are some model to be considered:

    • Prusa i3
    • Mendel90
    • Mendelmax 1.5
    • Mendelmax 2.0
  • #Prusa i3

    Wiki Page

    Advantages

    • Smaller build volume
    • Actively designed.

    Disadvantages

    • Less rigid compared to Mendelmax, which would compromise speed.
    • Less popular in the community which means less available support.

    Notes

    • Design track includes options for wooden sheet and box frames.

    Box frame file

  • #Mendel90
    Advantages

    • Simple frame design can be built from wood - less cost and easy to find.
    • Rigidity along the X-axis

    Disadvantages

  • #Mendelmax 2.0
    Advantages

    • Metal frame design is rigid and looks clean
    • Larger printing area than other Reprap designs
    • Can print faster than other Reprap designs

    Disadvantages

    • Potentially expensive because of custom metal parts.
{"cards":[{"_id":"3572a281bbeaeac5f9000016","treeId":"52221e79f138aca243001d09","seq":1,"position":1.25,"parentId":null,"content":"# Overview\n\n3D printing can afford relatively fast iterations in the manufacture and design of a physical product. The goal of this project is to research, source and build a 3D printer that can print in a high enough quality to allow for reasonable discussion and exploration, providing a cost effective, lower fidelity thinking step before moving to more expensive, higher quality steps such as laser sintering, stereolithography or casting.\n\nA Fused Filament Fabrication type designs offer the most practical choice for an affordable 3D printer right now."},{"_id":"3660532cf0902cdf21000012","treeId":"52221e79f138aca243001d09","seq":1,"position":1.6875,"parentId":null,"content":"#Printer Types\n\n**Laser Sintering**\n\n[Laser sintering](http://en.wikipedia.org/wiki/Selective_laser_sintering) uses a high powered laser to fuse a product's layers from a bed of powdered material.\n\n[Example on YouTube](http://www.youtube.com/watch?v=wD9-QEo-qDk)\n\nPatents currently keep laser related 3D printing out of reach of the hobbyist. These patents expire in 2014.\n\n** Fused Filament Fabrication **\n(same as Fused Deposition Method but not trademarked)\n[Wikipedia](http://en.wikipedia.org/wiki/Fused_deposition_modeling)\nAn additive method of 3D printing where material is put down in layers. A heated nozzle melts thermoplastic material and puts down the beads of material in layers, which cool and harden immediately."},{"_id":"3572f6a7bbeaeac5f9000024","treeId":"52221e79f138aca243001d09","seq":1,"position":2.125,"parentId":null,"content":"# Design Considerations\n\n**Print resolution**\n\nA reasonable target quality for this project is 100 microns, or 0.1 mm. This is on par for many popular 3D printers available for purchase today.\n\n**Build and Maintenance Cost**\n\nCost is another consideration. Cheap is good, as long as the build quality does not suffer. Ordering parts overseas (China) is not a time issue as shipping can take as little as 1 week, and can be a minimal cost. Overseas parts can often be subject to less distribution in NA, sometimes resulting in fewer public reviews of sourced parts.\n\n**Printable Material**\n\nABS and PLA plastics are common choices for print material. A hot print bed increases build cost but can prevent warping that sometimes happens when printing larger parts.\n\n** Rigidity **\n\nRigidity is a major factor in achieving quality prints at a higher speed. The inertia of the moving metal print head can cause the printer frame to shift while printing, causing inaccuracies in subsequent layers.\n\n** Tuning **\n\nA printer must have accurately repeatable, perfectly straight axis movement to ensure print layers are aligned. The printer frame design can accommodate adjustments. "},{"_id":"365f4b07f0902cdf2100000d","treeId":"52221e79f138aca243001d09","seq":1,"position":2.5625,"parentId":null,"content":"#Printer Location\nWhere are we going to store and operate this thing?? 3D printing can be noisy. None of the designs we are considering include a housing design to reduce printing noise.\n\nCan we get someone to sponsor a location? Can we buy a cube van to 3D print Breaking Bad style?"},{"_id":"3572bd43bbeaeac5f900001a","treeId":"52221e79f138aca243001d09","seq":1,"position":3,"parentId":null,"content":"#Models\n\nThese are some model to be considered:\n\n* Prusa i3\n* Mendel90\n* Mendelmax 1.5\n* Mendelmax 2.0"},{"_id":"3572c4e0bbeaeac5f900001d","treeId":"52221e79f138aca243001d09","seq":1,"position":3,"parentId":"3572bd43bbeaeac5f900001a","content":"#Prusa i3\n\n[Wiki Page](http://reprap.org/wiki/Prusa_i3)\n\n**Advantages **\n* Smaller build volume\n* Actively designed.\n\n**Disadvantages**\n* Less rigid compared to Mendelmax, which would compromise speed.\n* Less popular in the community which means less available support.\n\n**Notes**\n* Design track includes options for wooden sheet and box frames.\n\n[Box frame file](https://docs.google.com/file/d/0B5KQoskdsdeDNEFpTTY0ZmdSQjg/edit)"},{"_id":"365f6521f0902cdf2100000f","treeId":"52221e79f138aca243001d09","seq":1,"position":1,"parentId":"3572c4e0bbeaeac5f900001d","content":"#Prusa i3 Source\n\nhttp://reprap.org/wiki/Clone_wars:_Prusa_iteraci%C3%B3n_3"},{"_id":"35a3e8adb67faf99fc00000b","treeId":"52221e79f138aca243001d09","seq":1,"position":4,"parentId":"3572bd43bbeaeac5f900001a","content":"#Mendel90\n**Advantages**\n* Simple frame design can be built from wood - less cost and easy to find.\n* Rigidity along the X-axis\n\n**Disadvantages**\n"},{"_id":"365fcfd5f0902cdf21000010","treeId":"52221e79f138aca243001d09","seq":1,"position":1,"parentId":"35a3e8adb67faf99fc00000b","content":"#Mendel90 Source\nhttps://github.com/nophead/Mendel90"},{"_id":"3572c5b1bbeaeac5f900001f","treeId":"52221e79f138aca243001d09","seq":1,"position":5,"parentId":"3572bd43bbeaeac5f900001a","content":"#Mendelmax 1.5"},{"_id":"3572c558bbeaeac5f900001e","treeId":"52221e79f138aca243001d09","seq":1,"position":6,"parentId":"3572bd43bbeaeac5f900001a","content":"#Mendelmax 2.0\n**Advantages**\n* Metal frame design is rigid and looks clean\n* Larger printing area than other Reprap designs\n* Can print faster than other Reprap designs\n\n** Disadvantages **\n* Potentially expensive because of custom metal parts."},{"_id":"365f605cf0902cdf2100000e","treeId":"52221e79f138aca243001d09","seq":1,"position":1,"parentId":"3572c558bbeaeac5f900001e","content":"#Mendlemax 2.0 Source\nhttp://www.mendelmax.com/2013/06/23/mendelmax-2-0-sources-released/"}],"tree":{"_id":"52221e79f138aca243001d09","name":"3D Printer Build","publicUrl":"3d-printer-build"}}