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Post date: Oct 24, 2017 6:49:35 PM
The Final Project:
When I started my project, my vision was a foldable and compact enclosure for the makergear 3d printers at school. My source of inspiration my 3d printer at home which currently had an enclosure and could print ABS. I planned on using wood and acrylic. when I started with seven pieces, but ended with six. I decided to scrap the bottom when I began prototyping. Another design I decided to get rid of were the vents on the side as I wanted minimal air coming form the out side. After many classes and nights designing, I laser cut everything in cardboard. My initial way of making it foldable was with hinges, but after talking with Mr. D., I decided to make it magnetic. I used a system of washers and magnets in order to make it an easy setup. Unfortunately, I was not able to cut my final out of wood or acrylic because of time, but I am still very happy with my final result. If I were to do this again, I would have looked more at my enclosure, and added the magnets in the beginning as time was crucial. I also would have tried to find a way to make the enclosure even smaller. If you would like to see the final product there is an image on the last post.
The First Step:
The Idea for this project is to create an enclosure for the 3d printers so that it would be better suited for ABS printing. This is because it will create a better airflow inside, and there will be less influence of outside air on the printer. I will make everything but the front out of wood, and the front will be made out of acrylic. I will need hinges to keep it foldable and it will take less space. The bottom will have holes in it so the tabs on the sides can have a friction fit. It will have a door on the front if something needs to be adjusted in between prints. The top is removable so that the filament can be changed. There is space in the back for the wires, and there is a hole in the front for the computer cable. There will be vents on the side, so that the air is not completely trapped in side. Also, since the extruder only moves on the x axis, the top will have a thin rectangular hole for the filament to go back and forth.
10/12/17
Today during fablab, I made the frame for the cardstock prototype. I didn't have enough time to attach the tabs on the prototype. I also didn't have enough time to make the top or bottom. Mr. DiGiorgio told me that he wasn't sure if he wanted a door, so I will have to check on that tomorrow. He also said not to make the back hole so big and to check out his current enclosure to see what I can improve on.
Image of Current Model:
10/13/17
Today during class, I started the bottom. I also finished to tabs and the lid. I decided to add tabs on the side so that the walls would be stable add wouldn't move during prints. I changed the top to being attacked by hinges, but I am not sure I want to keep it this way. I also asked Mr. DiGiorgio about the door and he said to think of different ways of incorporating the door.
Bottom: Lid: Tabs:
10/17/17
Today during fablab, I was successfully able to create tabs on the bottom. I had to tape down the tabs for now because I could not get an exact friction fit because of having to cut using an exacto knife, but it should be fine when I laser cut it. I also changed the top from hinges back to a friction fit with tabs on the underneath of the top. If I were to have used hinges, you would have to unload and load the filament every time. I also added the slot for the filament to go back and forth during prints. On the spool side, I created a hole for the filament to pass through the side.
Updates:
10/19/17
Today during fablab, I am approved to start designing! Mr. DiGorgio told me that he didn't want a bottom so, I will no longer have one. I was about to start designing, but unfortunately the 3D printers were being used. I had the measurements, but I wanted to be a hundred percent sure. I went on the website, and extended the measurements on the machine by one inch. I will measure everything tomorrow during free block.
(Kept images large because the grids messed up the view)
Front: Back:
10/20/17
Today I came in during a free block to get the measurements for my enclosure. I continued designing in inkscape. I was successfully able to get the measurements for the sides, front, and back, but left early because I wanted to study for my physics test next block.
Updates:
Side w/ Spool:
10/23/17
Today during class, I have finished some of the designs for the enclosure. I completed everything but the top which I hope to complete by next class. I the enclosure measures 15.5 by 22 by 18 inches. The side with the spool took up most of the class as it took a while for me to get the precise measurements. I decided to stay after class and I now have a first model of the enclosure. I talked to Mr. DiGorgio, and he told me to extend all the gaps and holes. He also told me to add a circle on to the filament spool. He said to just expand the hole in the back and remove the hole in the front for the usb.
*Make Slots, holes, filament pass wider and bigger.
Current Designs:
Side w/ Spool: Side no Spool: Front: Back: Top:
10/24/17
Today during Fablab half the class cleaned up the fablab while the other half gave feedback about the blogs. People told me that my blog looked really good. I also typed up part of the instruction for the 3d printers. Also Mr. DiGorgio gave feedback to my blog to the entire class (I raised my hand when he asked if anyone had a working blog) and said that it looked good, but it need more lines. I went back and added some more information and context about the last couple of blogs as they were only one sentence each. He said that I did a good job adding labels and pictures. Unfortunately, I do not have much more to talk about because most of the class was used for catching up on the blog and cleaning up the fablab. I look forward to getting back into the fablab on Thursday as I have double freeblock and Fablab. The only issue I have is that I need big pieces of completely untouched cardboard as most of my parts are just under the limit of cutting.
10/26/17
Today during fablab and freeblock, I started laser cutting. I expanded the hole for the filament to pass through just to be safe. When I went to laser cut the first time, the laser cutter tried to go off the screen because the sides were exactly the vertical distance as the laser cutter. I then asked Mr. DiGorgio for help, and he told me to remove the lines on the top and bottom. This fixed the issue. I then cut the front and the back. I didn't cut the side or the top yet. I want to put back the cardboard prototype. The sides should be just a little bigger for my final model. I wonder when I put the hinges on, if it will push the front jus a little bit so that it is a tight fit.
Laser Cut Parts:
Back: Front:
10/31/17
Today during fablab and freeblock, I spent the majority of my time laser cutting. I was able to laser cut the rest of my enclosure. I noticed that the side with the spool was little to small towards the front. It should be able fixed if I add an extra 1/2 inch. I tried to set up the enclosure, but with out the hinges holding everything together it kept on falling apart.
Newest Laser Cuts:
Top: Side no Spool: Side:
11/1//17
Today during class, I prepped my designs for laser cutting. I recreated all the outlines of some of the designs by removing the top and bottom lines for the designs that had taken up the entire length of the machine. I also edited the designs so that the sides were 1/2 and inch longer.
Update:
When I got home today I started to 3d print the prototype version of the hinges. I have been work on the design for a while, but have not blogged it till now. Sorry I do not have any of the other versions as I have thrown them away, but I will include the designs for the previous versions. I started off with sort of block designs then I fillet the edges to get a rounder edges in order to allow for more mobility. I also cut out holes on top in case I would be using screws.
October 26 October 27 October 28 October 30
11/2/17
Today I tested to see if my enclosure would work. I used tape as substitute hinges as I only had two. I asked Mr. DiGorgio to see if it was good. He told me to add a little squiggly part where the filament tube lives in order for there to be an easier removal. Then I noticed that I need to add a little hole where you can stick your finger in order to open the front door. He also told me to add a little piece on the side with no spool so the door wouldn't fold in.
11/4/17
At home, I started my 3d printing the hinges. I went back to my hinge design in Fusion 360 and filled in the holes as I will be hot gluing them on. I also made the ends of the pole attached to the hinge so that it wouldn't fall out. I then exported it to the flashprint slicer, and duplicated it three time. I planned on printing eight of them. In hind sight I could have just printed it all at the same time but I didn't want to risk the hinges peeling off the build plate.
Images of 3d printing:
Fusion 360 Design: Flashprint: 3D printing: Hinges
11/6/17
Today I laser cut the tab to put on the side w/ no spool. I also used a box cutter to cut out the squiggle part on the top part of the enclosure. I realized that I had forgotten to get the redesigned hinges. The first time I hot glued to the hinges, I noticed that there was a gap from where the hinges bend. I talked to Mr. DiGorgio and he told me to move the cardboard up. I measured and set that the end of the hinge should be 1.6 inches from the end. I hope that this does not affect the height of the top. I need to sort all these out soon so that I can start laser cutting wood. I have been thinking about countering the size of the acrylic door to make it so that it does not keep on scraping on the edges.
11/6/17
Today I put on the real hinges on the prototype and tested it out. I had some failures as I either put the hinges a little to high up or to low. I was successfully able to get the right position of the hinges so that there was no gaps when extended. I achieved this by putting one of the pieces on the wall and then pushed the other on it. I did notice that the side with no spool moved away when I put the enclosure on the 3d printer. I will be adding another tab on the side for it not to move. This would interlock the hole for pulling the door.
Enclosure on 3d Printer:
11/9/17
Today during freeblock I add in the tab I talked about in the last blog. I just cut it out with and xacto knife, it wasn't perfect. I then hot glued tot the closet I could get to the hole in the front. This worked out pretty well. I then put the enclosure on the 3d printer to test it out. I found that the extruder set need a little bit more room for movement. I will be expanding this in the design.
Additions:
Tab on Tab: Slot on Top:
11/10/17
Today during Fablab worked on updating my laser cut files to accommodate for the changes. I mad the gap on the top bigger and improved the tab system. Then I asked Mr. D to critique my enclosure before I laser cut with wood. Then Mr. D threw me a curveball. He told me that instead of hinges and tabs I should try to use magnets and Velcro. At the beginning of my project I had thought about using magnets for the door but not the entire thing. Now that I am considering it I think that it would be better for the overall setup and design.
Freeblock
During Freeblock I spent my time trying to choose a magnet to use. I found this small powerful magnet that would work. It is 3/8 in and it is thinner than the thickness of the wood. I am going to keep it as .374 in the design because when the laser cutter goes through, it will burn off a little bit.
11/12/17
Today at home I have been thinking about the design I want to do with the magnets. I am thinking to put tabs on the side of the of the two sides. These tabs will contain a magnet that will connect to another magnet or washer depending on the amount that Mr. DiGiorgio orders. On the out inside of the back and front will be a space for the magnets (I want to engrave deeply so that it rests inside). For the door, I will keep four pieces of wood half cut into so the magnets can rest. The only thing about this, is that I can only engrave on one side, so the magnet will be on the inside. I am hoping that the magnets will be strong enough to hold the door up. Now the door (which will be the only acrylic part) will also have holes for engraving. I am still not sure about the top, but I am probably going with my original tab idea.
Updated Inkscape Files (When I made them Small, The lines on the Top and Bottom Started to disappear):
Door: Front: Side w/ Spool Tab for Sides
11/13/17
Today during Fablab, I tested and laser cut out the tabs for the magnets. The settings I used for the half cut was 25 speed and 100 power for the engraving and the normal settings for 1/8 in wood. I did 25 speed because it was a little about the 18 speed for cutting but way less than the normal speed for engraving. I also decided to use wood glue in order to keep the magnet in the tabs. I decided to go through a cardboard tests before I cut the actual design out of wood.
Things I Laser Cut:
11/15/17
Today during Fablab and freeblock I tested using a washer instead as I waited for the magnets to come in. I was successfully able to get it to fit in with a hammer. Feeling confident in my designs, I asked Mr. D. if I could laser cut with wood. Of course he said no. He told me to first test it out by hot gluing the tabs on the cardboard prototypes, so I measured the space out. During my hot gluing, I realized that if I put all of the tabs on the top 1/8 away, the top magnets would not touch. Now I edited by design so that the top two side cut outs are 2/8 in from the top.
Update
I finally got the magnets needed for the design. I got 36 3/8 in magnets. This may seem overkill, but I wanted to make I had enough as they were said to be very brittle and I planned on hammering them.
11/16/17
Today during freeblock, I lasercut some more of the tabs to put on the cardboard prototype. I was able to finish both of the sides making sure that each magnet faced the right way. I also put the magnets on the door by just hot gluing and again I realized that there was another problem with my designs. If I kept the magnets exactly 1/8 by 1/8 away from the edge, there would be a gap. I can fix this by shifting the magnets over by 1/8 of an inch on each side. I hope to finish the new prototype tomorrow during class and laser cut next week. If not I will complete next semester.
11/19/17
Today during Fablab is also the last class. Unfortunately, Mr. D. was not here and Tommy had to leave early. I was able to finish my prototype except for the door as that would require an entire new cut. For the top I just used an xacto knife so that it would fit, and I put each magnet 7 inches in. I used washers for the front, top, and back instead of magnets because of the power of the two magnets pulling together would dislodge the door and front magnets off. The prototype was successful, but I was not able to cut out of wood because I was not able to get approved because both of the people who I could ask for approval were not there. So unfortunately I was not able to complete my project, but I am hoping to finish it next semester.
Final Prototype:
Prototype Parts:
Back Side w/o Spool Back of Front Back of Back Bottom of Top
Side w/ Spool
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