Alan's 2550 Kossel Build

[gestalt73]

So, I've been working on a kossel design that scales up to Rostock Max proportions.

It uses Misumi 2550 extrusions.

Leveraging Xnaron's magarms and effector design, and bubbasnow's dual e3d clamp design.

I've made a few changes to the kossel design that should allow it to scale, and increase rigidity, and redesigned the hotend to accomodate two E3D-V5s above the effector plate.

Here are some super shiny renders of the final design.

I've already printed out samples of the lower frame, and I've printed out the complete effector, which I'm using on my Rostock right now.

The geometry of the kossel should allow full 300mm diameter printing with a single extruder.

[img]https://i.imgur.com/OdoukSt.jpg[/img]

[img]https://i.imgur.com/1AUdsnu.jpg[/img]

[img]https://i.imgur.com/uvj1tHq.jpg[/img]

[img]https://i.imgur.com/CYIx8a1.jpg[/img]

[img]https://i.imgur.com/jzYyiO5.jpg[/img]

[gestalt73]

Test print of the frame_bottom and 2550 fitting:

[img]https://i.imgur.com/nnLx8Gz.jpg[/img]

Test print of carriage:

[img]https://i.imgur.com/NvKZbTa.jpg[/img]

Printing and assembling the hot end:

[img]https://i.imgur.com/pRqsR9k.jpg[/img]

[img]https://i.imgur.com/tcJCQ6j.jpg[/img]

[Eaglezsoar]

A nice design and a great looking printer.
Excellent job!

[gestalt73]

Quick update after getting distracted for a while. Printed out the rest of the frame parts, and test-assembled the frame.

Still not 100% sure how I'll be attaching the build plate yet, and I'm finishing the design on the limit switch blocks this week.

[img]https://i.imgur.com/C5xcCgs.jpg[/img]

[gestalt73]

Quick update on the custom 2550 build. It's alive and well, and has been working flawlessly since final assembly last year.

I've got to tell you, this thing is silent, fast, and accurate.
I think I may be the first person to effectively use a damper for the cold end. You can just barely see it between the extruder frame and the nylon bracket.
The loudest thing on it is the squirrel part cooling fan followed by the hot end fan.
It can run all day sitting right next to me without driving me crazy.

It shares the same effector design as my Rostock Max V1, so I can interchange the Volcano for large prints or the Cyclops if I'm bored.

Also, 626Pilot's Smoothieware auto-calibration routine is a godsend. Thanks!

Build highlights:
- Using 2550 frame pieces (very rigid)
- 0.9 degree steppers (higher resolution movement)
- 16 tooth pulley gears (higher resolution movement)
- SeemeCNC 310mm heated plate and glass
- Xnaron's magnetic arms
- E3DV6 hot end
- custom effector design
- Smoothieboard
- GLCD
- geared stepper for extruder
- SeemeCNC cold end kit
- dampers for all steppers, including extruder
- ghetto mounted led lighting
- ghetto PVC spool holder


[img]http://i.imgur.com/7L8atEXh.jpg[/img]

[plasma]

Nice Job, Beautiful Build !!!

Would you be interested to share your STL files for the frame? And what length of 2550 extrusion did you use to get the scale.

[Eaglezsoar]

A very good job especially with the magnetic arms. We have to see the print quality that this produces.

[gestalt73]

Oddly enough, I have a couple of good samples lying around from current projects.

All three of these are printed at 100micron.

On the left is the bolt from the thingiverse planetary gear set. It's a fun print that helps to dial in for small parts.
http://www.thingiverse.com/thing:23030

Center and right are parts to give my InMoov robot another degree of rotation in the head.
I modified these parts to make it a bit easier to assemble.
http://www.thingiverse.com/thing:1243403


http://i.imgur.com/zScOjTS.jpg
[img]http://i.imgur.com/zScOjTSh.jpg[/img]

[gestalt73]

After some great success upgrading a client's machine to the Duet Wifi, I ordered a couple more for my machines.

This part of the upgrade moves to a meanwill 350-12 with low profile fan and Duet Wifi.
With the aftermarket fan, the entire setup is almost silent.
The 12v PSU is adjusted up to 14v, and total power draw under full load is around 250 watts.

There's just enough room there for everything, and the voltage drop under full load is less that 0.5v
Now that I've removed the pc power supply, I can move to two rails, and the base height is only 100mm.
The new z-height is 356.2mm.

I posted a quick youtube clip in the forum, this board redefines quiet. Not silent, but getting closer.

[img]http://i.imgur.com/bSniRXOl.jpg[/img]