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Building the first prototype

A project log for CHANGER - a toolchanger new interpreted

CHANGER - a motion system which can be used for advanced 3D-Printing with up to four materials, PnP, PCB-Milling, Layer inspection, etc...

simon-wirzSimon Wirz 03/27/2021 at 10:210 Comments

The last three months I was able to build the first prototype to a proper state. I'm trying to give you a short overview over the build process over the last couple of months so you'll get a feeling of the hole build process involved. 

The current state in words:

- Frame complete

- Motion system working with all endstops required

- All Fans working (exhaust fans, radiator fans)

- Watercooling pump working

- LED Light integrated and working

- Homing procedures successfull, Toolhead-coupler as well

- True bed leverling (G32) is working as well (best Milestone until now)


The build:

All the profiles and sheet metal plates could be mounted quite easily. First I had to thread all screw holes which took probably 2-3 hours. 

For the proper alignment I've used a large precision angle. Without such a large angle you're having probably quite the struggle to proper align the frame because of it's size. First I've used the middle extrusion for reference and tightend the backpanel. Of course you'll have to align in both directions (90°). With the backpanel (3 extrusions) fixed you can mount the top plate (CoreXY-Plate) and start to align the two extrusions at the front. Because of the independend Z-Axis setup you'll have to align the hole range of motion of the z-axis otherwise the kinematic coupling will jump out if not properly aligned. This process took me around a hole day. 

The electronics:

Next up the electronics. I've designed the printer so you can use proper DIN-Rails for tidy cable management. After the installation I'll love the idea of the simplicity and expandability. In the picture you can see three black parts with a metal insert in the middle. These are for a second DIN-Rail in a second level. The first level ist for main-electronics and therefore essential and the second layer is for the cabling of the Toolheads etc.

The watercooling:

For the watercooling loop I've tried to use proper hardtubes (PC-Casemodding) to have a proper cooling loop. I'm quite happy with the result of my first hardtubing. I've used PETG-tubes with a silicon core to bend the pipes over a heatsource. the silicon core helps to get an even bending without kinks.

LED-Lighting:

A proper lighting concept can work in your favor regarding the overall printer appearance. I've implemented long LED-Bars inside of the both extrusions in front. Therefore I've printed proper LED-Holders for the extrusions. 

The led-lighting can be switched on and off and you can reduce the brightness. The light is so bright you can't look from the back at the printer but you see every detail. Personally I think the lighting is perfect for such a printer.

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