Reprap Busby

What's the future of 3D printing technology? Wearables. Therefore, a wearable 3D printer.

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What is it? It's a 3D printer that's also a hat. I call it the Reprap Busby, the only biologist I could find that's also the name of a style of hat.

It's a printer that fits entirely inside a 150mm cube. Why would anyone want that? Because wearables are the future, and I'm making wearable manufacturing a reality.

The real story is it's just a very small printer with a 50mm^3 build area. CoreXY mechanism, heated bed (because when the bed is only 50x50mm, it's pretty easy to heat), bowden extruder. It'll end up being the printer we install in the Hackaday Van.

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  • A completed chassis

    Benchoff09/11/2015 at 17:22 1 comment

    Finally, after about two kg of filament (mostly failed prints), the chassis is done. From now on, it's an integration task - installing motors and wiring electronics. The body is done.

    Shot of the competed printer with a can of coke inside. Yep, it's small. Here's a comparison shot with a Makerbot Thing-O-Matic:

    How about a comparison between machine size and build volume? The Thing-O-Matic is 300 x 300 x 400 mm, with a build volume of 100mm^3. The ratio of build volume to machine size for the Takerbot is 1:36.

    My machine is 150mm^3, and I should have a build volume of 45mm^3. That's close to a ratio of 1:27. My machine has a larger build volume to machine size than a thing-o-matic. Of course that's a terrible metric, but it is a statistic I will be using for the inevitable million dollar kickstarter.

  • Mechanical Demo

    Benchoff07/30/2015 at 02:01 0 comments

    Finally got some 3mm rods from china, and spent a few hours stringing this thing up with 100lb fishing line:

    Next steps are to get the motors working and running the entire thing for a few days. Then it's modeling the complete printer. Woo.

  • What I would give for McMaster Will Call

    Benchoff07/19/2015 at 19:38 0 comments

    Right now I am waiting on 3mm drill rods. I got a ton of them from China pretty cheap, but the waiting is going to be insane. I have, however, completed the CoreXY stage. As soon as I get those rods, I'll be able to assemble the XY carriage and see if this thing will work.

    I've changed the completely printed XY stage so the rods are lined up with the small 'pulleys' I'll be using:

    That's a 3mm gap between two captive nuts. It couldn't have worked out better.

  • Really God Damn Small

    Benchoff07/10/2015 at 05:34 0 comments

    Mounted the XY motors and the rails. That's an Arduino in there:

    Started working on the XY carriage. That's an e3D hotend there. This is really small.

    Yes, it's extremely small. However, if I can get this to work I will have at least a 50x50mm build plate. That's two inches by two inches. Incredible.

  • PCB Heat Bed

    Benchoff07/07/2015 at 03:02 0 comments

  • This is becoming an increasingly stupid project

    Benchoff07/06/2015 at 19:23 0 comments

    Have you ever gotten to the point in a project where you just have to step back, look at everything, and say, 'this is really, really fucking stupid'?

    I have reached that point.

    That's an e3d hotend in there. That's also the z carriage at its maximum extents, a build volume of one cubic inch.

    My god this is a stupid project

  • Z Stage

    Benchoff07/06/2015 at 00:06 0 comments

    Required Components:

    • (2) 8mm ground rods
    • (2) LM8UU Linear Bearings
    • (1) 1/4"-16 Acme rod
    • (1) 1/4"-16 Acme Hex nut (height 13/64")
    • (1) 15 Ω 15W wirewound resistor
    • (1) MIC6 build plate
    • (1) Printed Part

  • CoreXY Stage

    Benchoff07/06/2015 at 00:00 0 comments

    Required Components:

    • (1) Synchromesh Cable - Metal and Diego are the guys for this
    • (2) NEMA 11 motor
    • (4) LM3UU Linear Bearing
    • (2) 3mm ground rod
    • (8) sleeve bearings
    • (4) 4-40 Nylock
    • (8) #4 Washer
    • (4) Nylon washer
    • (8) M2.5x6 socket head screws

  • Yeah It Fits

    Benchoff07/04/2015 at 16:34 0 comments

    module stepperHoles(){
            cylinder (h=15, d=3, $fs=0.01, center=true);
            cylinder (h=15, d=3, $fs=0.01, center=true);
            cylinder (h=15, d=3, $fs=0.01, center=true);
            cylinder (h=15, d=3, $fs=0.01, center=true);
        cylinder(h=15, d=15, $fs=0.01, center=true);
    module yAxisRods(){
                cylinder(d=3, h=110, $fs=0.01, center=true);
                cylinder(d=3, h=110, $fs=0.01, center=true);    
    /** Create a hexagon. * * The 'size' parameter specifies the 
    distance from the center of the * hexagon to the center of 
    one of the six straight edges. The 'depth' * parameter specifiesthe size in the Z axis
    module hexagon(length, depth = 2) {
        width = 2 * length * tan(30); 
            cube(size = [ length * 2, width, depth ], center = true);    
            rotate(a = [ 0, 0, 60 ]) { 
                cube(size = [ length * 2, width, depth ], center =  true); 
            rotate(a = [ 0, 0, -60 ]) { 
                cube(size = [ length * 2, width, depth ], center = true); 
    module outerBearings(){
            cylinder(d=3.175, h=15, $fs = 0.01, center=true);
                hexagon(3.25, 7);
            cylinder(d=3.175, h=15, $fs = 0.01, center=true);
                hexagon(3.25, 7);
    module plate()
                cube([135,125,10], center=true);
                cube([28.2,28.2,32], center=true);
                cube([28.2,28.2,32], center=true);
                cube([90,90,15], center=true);

  • Uncomplicated Math

    Benchoff07/04/2015 at 03:00 0 comments


    With actual numbers:

    Fuck it, bolt one of these fuckers on:

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Enjoy this project?



zachary_marlow wrote 01/23/2016 at 17:28 point

This thing is awesome I would buy one of those if its at the right price.

  Are you sure? yes | no

Alex Rich wrote 09/14/2015 at 23:30 point

Brian - the x/y mechanism is crazy, where'd you hear about that?  It's a cool concept but I notice you are still getting slack, not sure why.

  Are you sure? yes | no

Benchoff wrote 09/14/2015 at 23:33 point

Nick Seward has experimented with a core XZ, or basically a prusa i3 y carrage with a core xy rotated 90 degrees. It's an interesting mechanism that really reduces inertia. If you're using a bowden anyway, it's the way to go

This is *really* just a test for a printer I want to make in the future. It'll be a coreXY plate (so the x and y axes on a single sheet of aluminum), with the *plate* moving up and down for the Z. That's the best way I can figure to have a stationary build plate.

  Are you sure? yes | no

Alex Rich wrote 09/15/2015 at 00:18 point

oh, didn't realize corexy was a specific thing.  that's clever.  I notice you have to sync the motors either both in the same direction or opposite directions at equal speeds or you get slack.

  Are you sure? yes | no

MECHANICUS wrote 07/21/2015 at 02:48 point

Haha this is hillariously awesome, I want a RepHat Busby!

  Are you sure? yes | no

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