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Chris Purola (Chorca)
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632 followers
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Getting closer to printing! Drag chain installed, extruder built and installed, +Sanjay Mortimer's Chimera hotend with a Volcano installed on the machine. Got all the endstops put on and pushed through a couple bugs in Marlin to get things running smoothly. (Thanks for the help, guys!)
Tonight I got the bowden tube hooked up and got it extruding plastic! 0.60mm nozzle makes some BIG extrusion, can't believe what 1.0mm will look like.
I'm probably going to set up the Chimera with two different size nozzles to be able to print at different speeds and qualities depending on the part being printed. Have yet to test actual printing but the extruder and retraction is working well! I'm just a hair under 2' in 2 of the 3 dimensions, which is a small disappointment.
The MIC-6 plate came in today and it's heavy at 16lb! Now that the Z axis motors zero and sync up on home it comes into level. I need to better support the center as it's bowing slightly, I have some new rubber leveling feet on the way as well to support the bed from the frame. Still need to tidy up the bowden tube and support it somehow.

110V bed heater pad is on the way along with an SSR to control it. 
For electronics, the board is all wired up, along with a Pi2 onboard to run OctoPi. I'm hooking up a small 7" touchscreen monitor to provide control and status, a logitech webcam for timelapse, and it all runs off an ATX power supply.

The pressure is on! Next week is +Maker Faire Orlando  , and this is an exhibit there, so I've gotta get it working!

Pics:
https://i.imgur.com/kLawSqH.jpg
http://i.imgur.com/TiEZiv4.jpg
http://i.imgur.com/nB4Iclk.jpg
http://i.imgur.com/GAAcIeH.jpg

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What's cooking? PLA!
Testing out a dehydrator on some ruined filament cause of water. We will see how it works!
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It's working!!
Finally the big CoreXY lives! While the Z axis has been a bit of a pain (I built it in a silly way), I decided to let it sit for a bit while I made more progress on the X/Y portion of the machine. I printed out some new pulleys to help space out the belts a little and tensioned everything up, then gave it a whirl!

It's running the latest smoothieware and just flying all over at the moment, and everything looks good so far! It's gotten me excited enough to start working on the Z axis again to get it to stay level. I'm going to design some large mounting brackets to try and hold everything together down there.

Anyway, here's the video!

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Slowly but surely progressing on building this printer. Thinking of going with one of +Sanjay Mortimer's Volcano hotends on this thing considering the size. Most likely dual bowden extruders.
Built the bed support and got in the bearings and smooth rod for the Z axis. Put all the nuts in for attaching the motors and rod holders last night, just waiting on the right size screws to mount both of those.
Bed is reeeeally close to the 2' mark.. I'm doing my very best to make sure it's the full size.
Checked +OnlineMetals.com but the cost for a 1/8" sheet of 6061 cut to 25.5 x 25.5" is over $80 compared to about $45 for a 24 x 24" sheet. Might just have to bite the bullet on this one but that seems really steep.
Bought a couple sets of FSRs from +SparkFun Electronics and a couple ATTinys to see if I can build a little interface to make them simulate an endstop to the Smoothieboard for both Z-zero and ABL in case I can't get this huge thing perfectly flat.
Currently thinking up how I want to secure the alu to some mounts to make it easier to level. Possibly using some adjustable leveling mount/feet from Misumi.
The $20/4 set of 12mm LM12UUs from Amazon were utterly horrible. Almost unusable they are so rough on the rails. Gave up and ordered some $20/ea ones from VXB, along with a few extra bearings for various needs. They came in and they glide a lot easier.
Next up is to use my Fusion360 learnings to design an angle bracket to support the bed from the linear rods and get the motors and such mounted up.
Smoothieboard has been soldered up and I got in a ton of those little .100 female connectors and pins so I can wire up the machine really nicely.
If anyone's wondering, here's the current BoM for this printer:
https://docs.google.com/spreadsheets/d/1X_fdQz5mM7DW8g2rq9_sVLcrH3Q8iehfvIzOn8Jrn1o/edit?usp=sharing
It just keeps getting more expensive ;_;
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2015-05-20
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Demiglenn illustrates how I feel after this con.. Exhausted and happy though.
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I'm heeeeere!
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At the beer tasting at Elliot's spring gathering!
#esg2015
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Going to be using SmoothieBoard in my new printer, 2' cubed printable area, CoreXY motion.
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2015-05-05
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Well, still making progress on the big repstrap thing. Its coming along, but there isn't much info out there on CoreXY design.. I'm looking for fundamental stuff like which belts have to be parallel, sizes of idlers, if they can be different sizes or have to be the same, and if so, which ones? I'm gleaning what I can from photos and random bits on forums, but I'm forging ahead either way, so it will be a bit of trial-and-error or a lot.

Here's a few pics of some stuff in mocking up, feel free to let me know your experiences if you've designed a CoreXY bot!
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5/5/15
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