We have moved to Japan!

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Good news, everyone! Schorsch is now living and working at OIST, Okinawa, Japan. Don’t worry about his wooden body, the Lab he’s in has a nice dry atmosphere and he shares it with a lot of far more expensive stuff. So far he’s doing a good job, but the fancy new place with ocean view has a steady cold breeze from the AC above so i will have to do something about that.

He survived the 14hrs+ in a plane with minor injuries on Z. Luckily the parts that broke were meant to break in case of failure and i am quite proud that there were no further problems due to the loose, rocking Z-axis. X and Y arrived fully working, even the lines haven’t jumped off any bearing.  Remember to fix EVERY part that can move when you put your Printer on an international trip!

 

Speedtest

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Ok, Schorsch can print @ 220 mm/s and up. But since even PLA quits at these speeds the last layers of this gear are printed at 40mm/s… The first and  the middle part of that gear were printed with 100 – 220 mm/s (first layer ~20mm/s) to see how it works. You can’t really call it ‘printing’ since straight ‘printing’- moves look like normal rapid moves. The result is fightening ugly. I don’t think it is a good idea to print at those speeds. But it’s nice to know that Schorsch could.

It’s done.

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Dear world, i did it! I finally did it! I redesigned my printer. Today it printed it’s first things. Straight things, round things, 100% filled things. Now a case.

To be honest, i kept the old four-corners-four-motors-Z-axis… I just wanted to see new Schorsch printing! And how he does…

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But of course i ran into some struggles: Broken wires stopped the heatbed, the temporary magnet for the X-endswitch damaged the switch causing Schorsch to grind madly in the corner and finally loosing the A-line. While dealing with that i figured out that it is a good idea to move the head free with my hands to feel if there is a problem with the lines. If it misses one bearing it is much harder to move – prints start normal but at some rapid move it will loose many steps – and makes you a nice piece of crab. When both lines are jumped off – well, i din’t know.

For today’s over-night-print i reduced Schorsch’s speed to 350mm/s @ 10000mm/s² printing @38mm/s. I noticed the motors lost steps when heated +50°C. Maybe i reduce the current a little. 500mm/s schouldn’t be a problem with only one Hotend.

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Old Schorsch is now part of new Schorsch. New PSUs wait to replace the old chinese 1150W PSU on the right and the 15V for the heatbed. As you can see i am still stuck with 200x200mm²… enough to print its new Z.

btw. I removed the door of the nightstand because it was too loud.

Here’s new XY

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That’s right! New Schorsch is a 60’s nightstand that will leave future archaeologists clueless. The final dimensions are 345 x 205mm². An idea with consequences that kept me awake too long yesterday was to place the Y-endstop at Ymax – only the bugfixed RC of the actual (dec 2015) marlin firmware can handle that with coreXY enabled. The other branches kept Y useless after hitting Ymax…

While researching that problem i found a lot of people using or building coreXY-based printers – yeah! Some of them even use fishing-line! Strike! Now i’ll wait for more old-furniture-printers…

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His first steps

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It’s done. New SchorschXY’s XY-Stage is assembled. When the upper picture was taken i didn’t realize that there are not only two srews missing at that A-Motor. One hole winding on the pulley was also missing making it impossible for the Head to move to X0 Y0… turns out it ‘jumped’ of during montage and the hole 40mm where rolled on the tensioner. Schorsch is a pretty complicate thing. I like that.OLYMPUS DIGITAL CAMERAPutting on the line for the first time took me some time. I learned to love the ptfe-coating of the aramid-line – it helps a lot keeping the line in place even when not tensioned. AND i also learned that the A-line is much harder to install. I took tweezers a toothpick to fiddle it on the tiny 3mm wide BBs. But it seems quite robust when tensioned. OLYMPUS DIGITAL CAMERAFirst i put the ol’ Marlin Firmware on and started testing how it moves. There are no andstops yet. Schorsch runs save at 500mm/s @ 10000mm/s². I don’t think that’s realistic. OLYMPUS DIGITAL CAMERA

Update: Science!

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This is a cluster of eight dipoles. I did not thought about this until a few months ago when a friend came up with this at christmas. He told me that it would help him at work. So here it is! In this case the dipoles are represented by Toy-Magnets i had laying around. Each magnet sits in its own gimbal allowing free rotation around its centerpoint which is one corner of a 40mm X 40mm X 40mm cube. Manipulating one magnet forces the other ones to align. This is as fascinating as it is hard for me to explain. But don’t worry, Dr. Johannes Schönke will have a look at it.

(The screws in the picture might trigger some trolls. They are made of the least ferromagnetic stainless steel I found. But of course, there shouldn’t be any ferromagnetic part.)

Details of a nice print

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As previous shown, Gunnar Gerhardt has already made a lot of characters that slowly make it to the digital world. Here is a testprint of ‘Matchstickman’. I also printed it in white but as you may know: the natural white APS is almot photo-proof due to its translucency… so enjoy some more details in black:MSM_torso_detail01

By the way:

Layer: 0.15mm

Printing@ 10mm/s

Travel@ 200m/s

Acc@ 5000mm/s²

Temp@ 245°C

Matchstickman is around 110mm tall and comes from the 55mm original that got scanned with David-Laserscanner.

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Schorsch is [printing sth. that is] going near space!

ROCKET_Tip01Recently, a guy named Karl called me with his idea of building a Model-Rocket in order to start his new life in Rocketscience.

He already had everything but the cap so he sent me a Rhino-file with his calculated shape and now we have a few Caps that should make the Rocket go about 500m high. Above you can see the tip right out of the printer (left) and after sanding/acetoning (center, right). It is about 2.4g for the cone and another 1.2 for the bottom. After sanding and acetoning the should be 3.4g in total for the tip. Not that bad – with a .3mm nozzle they could weight around 2g at all!

Maybe the future will bring us some lower restrictions here in Germany so that we can use stronger Motors to lift something more than a few hundred meters…