Date: 23-09-17  Time: 00:26 AM

Author Topic: KerrB 3D Printer Kit @ The Foundry  (Read 504 times)

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Offline Jason Davies

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KerrB 3D Printer Kit @ The Foundry
« on: 2015-06-04 06:06 PM »
You may have seen The Foundry's exciting little 3D Printer we call "KerrB"  that we are developing with our resident mechanical engineering expert Jeff Kerr. Our goal is to release the plans for this printer as Open Source and to develop, produce and sell kits for it soon at a very reasonable price. But our next step down that road is a Beta Build.We are forming a team to develop the Beta build of the printer -- 2 brand new KerrB machines -- and help us to document the process with clear instructions, photos and video.
Volunteers need to be available to come to the Foundry on consecutive Thursday evenings in June for 3 weeks or so, probably a couple of hours each week. We will finalize all the timelines soon.
Some of the tasks that I know we'll be talking about are:
  • Planning out assembly manual & photography
  • Planning out video assembly instructions
  • Getting familiar with the KerrB operations
  • Sourcing electronic parts
  • Laser cutting some panels
  • 3D printing some parts
  • Milling a few aluminum parts on the Foundry's lathe & mill
  • Scheduling
  • Kitting and selling kits
Most urgent need is in metal machining for our 2 prototype machines. If you have used a metal mill or CNC Mill before to make accurate parts (Mark Benson and Alan Brewis, I'm looking at you!) we need a few parts milled soon.

Offline Jason Davies

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Re: KerrB 3D Printer Kit
« Reply #1 on: 2015-06-05 09:06 PM »
Order of events & List of participants
Thanks to all who came out to the first meeting of the Kerrby 3D printer project.
First off, what do you like better: KerrB or Kerrby? Jeff prefers the later...

Here is the order of events (as I estimate it) for this project:
    1.    Set up forum on Dialog DONE!
    2.    Pre-Documentation (ie taking notes on the process)
    3.    Photo & Video (setting up shots, & lighting)
    4.    Order parts
    5.    Mill aluminum parts
    6.    Cut laser-cut parts
    7.    3D Print parts
    8.    Printer A: Mechanical Assembly
    9.    Printer A: Electronic Assembly
    10.    Printer A: Testing / QC
    11.    Draft Assembly Manual
    12.    Printer B: Mechanical Assembly
    13.    Printer B: Electronic Assembly
    14.    Printer B: Testing / QC
    15.    Finalize Assembly Instructions
    16.    Draft Operation Manual
    17.    Finalize Operation manual
    18.    Add Appendix / Misc to manual

These brave souls have volunteered to lead the charge in these particular subjects:
Ordering parts
Jason Davies
Robert Sears
Brian Lindahl

Machining
Alan Brewis
Mark Benson

Laser Cutting
Jason Davies
Robert Sears
Brian Lindahl

3D Printing
Mitch Williamson
Brian Lindahl
Jeff Frohning

Mechanical
Mitch Williamson
Jeff Frohning
Doug Schoonover

Electronic assembly
Robert Sears
Mark Benson
Brian LIndahl

Photo
Brian Lindahl
Mitch Williamson
Alan Krum

Video
Brian Lindahl

Documentation
Lukas Sexton
Art Miller
Brian Lindahl

General Help
Doug Schoonover

We meet again next Thursday at 7pm!
-Jason

Offline Jason Davies

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Re: KerrB 3D Printer Kit
« Reply #2 on: 2015-06-12 11:06 AM »
Here is the BOM for the Kerrby 3D printer!
Lasercut files and 3D Object files to come later today (hopefully)
-Jason

Offline Jason Davies

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Re: KerrB 3D Printer Kit
« Reply #3 on: 2015-06-12 11:06 AM »
We didn't get a lot accomplished on the Beta project at our Kerrby meetup last night, but we did learn a bit more about the software used (Pronterface and Slic3r), learned how to calibrate the Z-axis, fixed the broken prototype machine and printed out the first part needed for the Beta project, the rocker arm located just above the nozzle!
Jeff has promised to send in the other files needed (the 3D object files & laser cutting drawing for the acrylic frame) today.

Offline Jason Davies

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Re: KerrB 3D Printer Kit
« Reply #4 on: 2015-06-14 08:06 PM »
Last Thursday we attempted to print our first part for the Kerrby and it failed kind of strangely...



I spoke with Jeff Kerr and he deduced that the "Y" axis belt was slipping, but just as it was travelling (ie not printing) from one side of the print to the other. This travel is very fast (since it doesn't need to apply filament) and it made the Y belt slip, causing this gradual slip in one direction.

Jeff tightened the screws and fixed it. And here is a photo of the part finishing up on the printer. This time in grey:


Success!!

Offline Jason Davies

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Re: KerrB 3D Printer Kit
« Reply #5 on: 2015-06-15 04:06 PM »
STL files for the 3D printed parts on the Kerrby!
https://drive.google.com/file/d/0B9-vAXbjykPhdDZ4cGdSdC1xaG8/view?usp=sharing

Here's Jeff Kerr's notes on printing the parts:
Hi Jason,
Here are the STL's for the printed Kerrby parts.  The MXL pulleys are probably the trickiest to print - you should set the perimeter line width to 0.35mm and also slow down the print speed to 30mm/s for perimeters, and 70% of that for the outer perimeters.
 
The rocker should be printed with 4 perimeters and a 35% honeycomb pattern infill.
 
The duct needs to be printed with supports but default supports from Slic3r will be very hard to remove.  I may have to slice it for you using Simplify3D with edited supports.
 
Jeff

Offline Robert Sears

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Re: KerrB 3D Printer Kit
« Reply #6 on: 2015-06-15 09:06 PM »
Here is the BOM for the Kerrby 3D printer!
Lasercut files and 3D Object files to come later today (hopefully)
-Jason

Are you looking for alternate or just cheaper sources?

Offline Jfrohning

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Re: KerrB 3D Printer Kit
« Reply #7 on: 2015-06-16 10:06 AM »
Found a slic3r tutorial.

http://richrap.blogspot.com/2012/01/slic3r-is-nicer-part-1-settings-and.html

I am more than happy to come in and volunteer time throughout the week.   Are we ready to cut the acrylic?  Are all the parts printed?

Offline Jason Davies

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Re: KerrB 3D Printer Kit
« Reply #8 on: 2015-06-16 05:06 PM »
Jeff, we are ready to print parts. Come on in anytime during member hours (Wed-Sun Noon-9pm) to work on this project.
We have the acrylic in hand at the makerspace but don't have the final art file for it (I believe Mr. Kerr is still tinkering with it!)

Offline Art Miller

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Re: KerrB 3D Printer Kit
« Reply #9 on: 2015-06-22 08:06 AM »
Sorry I haven't been keeping up on things!

Hey Jason, if you can save any parts that do NOT come out right, make a sticky note as to what happened and what the problem was and how to fix it, we can add a troubleshooting/common problem section to the documentation

Offline Jason Davies

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Re: KerrB 3D Printer Kit
« Reply #10 on: 2015-07-09 03:07 PM »
Hey guys
 Here's an update on our Kerrby project.
 ON AGENDA FOR TODAY:
 
  • We need to print a second set of 3D printed parts on the Kerrby,
  • Laser cut another complete set and a few replacement parts
STATUS REPORT
 
 
  • Electronic parts are on their way. Should be here by next Thursday (July 16).
  • 1 set of Laser cut parts are cut, need another set cut by Thursday. WHO WILL VOLUNTEER TO DO THIS? (Must have taken laser cutter safety class)
  • 1 set of 3D printed parts are cut, need another set. WHO WILL VOLUNTEER TO DO THIS?
  • Metal machined parts are made, thanks to Mark Benson and Alan Brewis
  • Still need a source for anodized aluminum. MARK BENSON, did you have a lead on that?

 NEXT THURSDAY:
 We begin assembly. We need:
 1 -2 people who havn't done this kind of thing before (Mitch W.? Jeff F.? )
 1-2 people that have experience in assembling 3D printers, CNC or the like (???)
 1 person to photo document (Brian L? Alan K.?)
 1 person to take notes on assembly process (Lukas? Art?)
 1 person to instruct the builders (Jeff Kerr)
 
Let me know if you will definitely be here today for some production work or next Thursday for the assembly process.
 
Thanks! I will also post this list to the Dialog.
 -Jason

Offline Jason Davies

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Re: KerrB 3D Printer Kit
« Reply #11 on: 2015-07-23 11:07 AM »
Kerrby Build Session, July 23, 2015

Hey everyone
 
 I'm looking forward to the build session tonight. It felt good to make some real visible progress on the 3D Printer and documentation last week. Let's keep it up and build some more Kerrby! Who's coming in tonight?
 
 Last Thursday we wrote down all the processes and took a lot of photos but did not take much video. Perhaps we should focus on photos for this printer and take videos of the process on the 2nd one we produce. Does that sound like a plan?
 
 Check out the files so far on the google drive:
 https://drive.google.com/open?id=0B2yK6tX5VTdOfkJDSWZHSmdlNXZLTWVUdGtiX1JqeEVLc3V2WFBraE1XMkI4OVEwUkIzZlU
 
 Thanks, and see you at The Foundry!