FOR RELEASE: BFP Design Notes and Documentation PDF
FOR RELEASE: BFP Design Notes and Documentation PDF
HI REDDIT
I am working on a PEEK filament Kickstarter and would love your support!
https://www.kickstarter.com/projects/ggalisky/cheap-peek
I am also working on V2, if you want to collaborate PM me
80% Submittal (First Draft) of BFP(Big FDM Printer) 3D Printer Project
By Grayson Galisky
2
Table of Contents
Introduction………………………………………………………………………………………….x-y
Design………………………………………………………………………………………….x-y
Manufacturing Plan…………………………………………………………………………….x-y
Assembly Instructions…………………………………………………………………………….x-y
Bill of Materials…………………………………………………….x-y
Design Concerns……………………………………………………………………………….x-y
Recognitiongs……………………………………………………………………………………….2-3
Introduction
This version of documentation is meant for release on the internet. To all those reading I
hope this helps you build your high temp 3D printer. If you have any questions feel free to email
me [email protected] and I will do my best to get back to you
The goal of this project is to build a 3D printer that has similar capabilities to a Stratasys
Fortus 450mc 3D printer(link:https://www.stratasys.com/3d-printers/fortus-380mc-450mc ). This
means the 3D printer must have a heated chamber, and a high temperature hotend.The
tentative budget is around $3000 for parts. I will not be including a second extruder for this
revision of the project. This version of the document is the 80% submittal version, which means
that this is the first draft.
Project Goals:
● High nozzle temperatures >400c
● Heated build chamber with a maximum temperature of 200c - Note In order to do this I
will need to have metal blower fans installed on the convection heaters in the chamber.
● Custom GUI on the panel due - this may take a while because I have to learn C++
● Large print volume
● Swappable bed surfaces - to make experimentation easy
DESIGN
OVERVIEW
4
FRAME DESIGN
Frame material comparison - table 1 frame material choices
4040 Aluminum extrusion Welded Steel Square tube
Pros Pros
5
XY GANTRY DESIGN
Overall design
The XY gantry is designed around COREXY kinematics (link:http://corexy.com ). The X and Y
axis utilize 15mm knock off HIWIN linear rails (figure 5 HIWIN linear rails) and linear bearings to
facilitate linear motion. While the CAD model shows that the X and Y axis are using 20mm
HIWIN rails I will be switching these to 15mm rails. Linear rails were chosen for this project
because of their relatively low cost and high precision. Data sheets for the rails can be found in
the datasheets folder included with this document. The Y axis rails are bolted aluminum
extrusions on the top of the 3D printer, and the X axis rail is bolted to the X Bar.
7
Steps per mm
Steps per mm will be calculated after I figure out what pulley size I am using through this
website:https://www.prusaprinters.org/calculator/
Belt Path - figure 6 belt path
The belt path for this printer follows the same corexy belt path seen on a DBOT
(link:https://www.thingiverse.com/thing:1001065)
Note - now that Filastruder is selling genuine gates belts and idler pulleys I may use those
instead after researching the differences link:
https://e3d-online.com/catalogsearch/result/?q=gates
The X bar is constructed with low cost aluminum angles to keep the bellows in place. It is made
from 10mm thick piece of aluminum. While it is not modeled, there will be threaded holes in the
X bar to mount the x axis linear rail. On either end of the X bar’s aluminum angles there will be a
clamping plate to secure the bellows. The X bar linear rail holds the extruder carriage. In
addition, the x bar has 4 threaded holes to hold pulleys for the belts.
Figure 9 X bar
The X bar mounts onto a linear bearing on either side, and those mounting points feature a slot
that allows for slight errors in the positioning of the Y rails - figure 10 X bar slotsillustrates this.
Hotend Choice
Titan aqua - This was purchased for the SST 768 refurb project and is rolling over to this
project. The Titian Aqua’s water cooling not only cools the cold end of the extruder, but also
provides cooling for the extruder stepper motor. The maximum heat rating for the extruder
stepper motor is 80 C. This is important because the placement of the extruder motor is only
insulated from the heated build chamber by a thin piece of glass fiber silicone fabric and 20mm
of air. To aid in the efficiency of the cooling of the stepper motor I have applied thermal grease
between the aluminum water cooling block and where the stepper motor mounts as per the E3D
assembly instructions. I will be pairing the Titan aqua with a copper E3D volcano heater block, A
.4mm and 1mm E3D Nozzle X, high temperature 24v heater cartridge and a PT100 cartridge
thermocouple. Figure 14 hotendshows an all of these components laid out
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Figure 14 hotend
Wires will be managed through either zip ties or a custom 3D printed cable guide. If using zip
ties the holes labeled in figure 15 carriage mounting holes and belt clampswill not be threaded
and zipties with go through them. If using a custom 3D printed cable guide those holes will be
threaded and used to mount the 3D printed cable guide. In both cases the extruder carriage has
mounting holes on top that allow for a 3D printed cable chain mount and wire management cap
to be installed.
13
BELLOWS DESIGN
Overall Design
Flexible bellows were chosen for this project to keep the heat from the heated build chamber
inside the 3D printer while the print head and z stage move. Having flexible bellows allow for
movement in the X, Y and Z directions with minimal heat escaping. Since the heated chamber
may reach temperatures of 200c, a silicone glass fiber fabric that has a maximum temperature
of 260C(500F) was chosen as the bellows material (datasheet and SDS attached). The silicone
fabric will be sewn with Kevlar thread because of its max temp of xyz. Figure 16 bellows design
shows how the bellows are designed and the lower photos are of the bellows system from a
stratasys F170.
14
Bellows equations
15
Note, both equations include an extra bellows unit to ensure that the bellow in their fully
stranded state never exceed a chosen maximum angle. These calculations will be fully filled out
once frame dimensions are finalized, however, z = 5mm, t = .432mm regardless of the frame
dimension assuming I am using a 17mil thick bellows material.
● L = the length of fabric in meters
● n = the number of units. A unit is defined as per figure 16 bellows unit
● X prime = the linear distance the bellows need to cover in meters
● t = the thickness of the material in meters
● H = 2z + y. z and y are defined as per figure 16 bellows unit
● 𝛳 = maximum angle a single bellows unit is allowed to extend and can also
figure 17 XY Bellows
figure 18 Z Bellows
Extruder Bellows - figure 19 extruder bellows
The extruder bellows are mounted to the x carriage.
17
Z STAGE DESIGN
provided from my supplier. Note - After performing static load calculations I found that a
25mm rail maybe overkill for my application.
figure 20 Z stage
single linear bearing. Since my design uses two linear bearings on either side of the build plate I
am positive that the build plate will be properly supported.
Holding Torque Calculations (Thank you Andrew, Will and Joaquin for your help on this)
The holding torque calculation is figuring out if the holding torque of the name 23 motors I had
would be sufficient for lifting and moving the z axis. This calculation does not solve for anything
relating to dynamic load and I need some help figuring out how to do those calculations.
20
The real holding torque of my name 23 will probably be 60-80% of the rated value given I will be
driving them at 2.4A rather than the 2.8A they are rated for. Converting to metric units and
assuming 70% of the maximum that leaves us with a holding torque of .882N-m. Plugging all of
this data into the formula below using 0 for the external force and 1 for μ (source
link:https://www.nidec.com/en-NA/technology/calc/torque/ball screw/) gives us a torque of
around .2N-m. Since our holding torque of .882N-m is much greater than the .2N-m needed to
hold the build plate in place the name 23 should be sufficient for this application.
OVEN DESIGN
Figure 28
Insulation Packing
28
Insulation will be packed into the walls of the printer as per figure 29 oven insulation. I will be
using fiberglass insulation salvaged from a household oven. Insulation will be held inside of the
walls of the printer using sheet metal panels fabricated from scrap.
Lighting
I will be using high temperature oven lights, and they will be mounted as shown in figure 30
lighting
figure 30 lighting
ELECTRONICS
29
Motors
I have selected 2.8A 179oz.in Nema 23 stepper motors for this project. Initially I planned to use
these on my SST 768 refurb build.
Here are some calculations about motors
https://3dprinting.stackexchange.com/questions/212/how-do-i-determine-the-acceleration-value-
for-my-printer
https://duet3d.dozuki.com/Wiki/Choosing_and_connecting_stepper_motors
MISCELLANEOUS DESIGN
Limit Switch Holders and Cable Chain Holder - figure 36 plastic parts
Both of these items will be printed in ABS. If they begin to melt I will print them in ULTEM.
Aesthetics
In the future I may add painted plastic panels on the outside of the printer to give it a more
professional look. These panels would be mounted on standoffs attached to the frame of the 3D
printer. An example of an implementation of plastic panels is on the Fortus 450MC - figure 38
Fortus 380 and 450mc
I currently have very little to no experience with machining parts out of aluminum or steel. I have
access to a drill press, manual mill, and a plasma CNC table.
Drawings of each part that needs to be machined will be produced after I review feedback on
my current design. In addition, an assembly guide will also be produced once all parts are
finalized. Below are some of the parts I need to make and the manufacturing methods I will be
using to make them. The photos are not to scale.
Example of parts I plan on making with a chop saw and drill press:
37
Design Concerns
“When the printer is enclosed and heated for printing ABS, the aluminum frame will expand, but
the steel linear guides will expand much less. As the frame expands, the Y axis linear guides
will move apart. If the steel X axis guide rail is solidly bolted to the Y axis bearing blocks, when
the Y axis guides start moving apart, the X axis will put huge side loads on those bearing
blocks, possibly causing the mechanism to bind. I addressed that potential problem by bolting
the X axis rail to only one of the Y axis blocks via the pulley mount. At the other end of the X
axis I used a second X axis bearing block (at the top of the X axis in the photo above) to
connect to the Y axis bearing block via the tubular pulley mount. This allows the Y axis rails to
move apart but fully constrains the X axis otherwise. It seems to be working well.”
This may not be an issue for me since my X bar is made of aluminum as well as my frame, so
as my frame expands so does the aluminum on the X bar. It also may not be an issue for the
design at all since there will be an insulation barrier between the aluminum frame and the
heated build chamber. In addition, the aluminum frame on my printer will be exposed to ambient
air temperature (or fans pushing air) and therefore may not expand to the point where it causes
binding - further testing and research is required.
Thank You!