OpticalTableRobot: Difference between revisions
From HacDC Wiki
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[[File:OpticalTableRobot.png|400px|right]] | [[File:OpticalTableRobot.png|400px|right]] | ||
Multi-tool CNC platform in progress atop the optical table to enable ultra-precise fabrication on a massive scale. Derived from | Multi-tool CNC platform in progress atop the optical table to enable ultra-precise fabrication on a massive scale. Derived from [https://github.com/mirage335/FlexReplicator FlexReplicator]. | ||
This is the kind of machine one might use to 3D print large herringbone power transmissions for lost PLA casting, or carry out a VLSI production run. | This is the kind of machine one might use to 3D print large herringbone power transmissions for lost PLA casting, or carry out a VLSI production run. | ||
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=Features= | =Features= | ||
* Approximately 7'x2'x1.5' build area. | * Approximately 7'x2'x1.5' build area. | ||
* Built on 100W Laser Cutter (tube down ATM) | * Built on 100W Laser Cutter (tube down ATM). | ||
* Rock-solid, supported by | * Rock-solid, supported by optical table and 40 series extrusions. | ||
* Supports multiple tools and capabilities, | * Supports multiple tools and capabilities, starting with 3D printing and Laser Cutting. | ||
* Simultaneous multi-tool use will enhance | * Simultaneous multi-tool use will enhance utility, such as milling down 3D printed layers. | ||
=Documentation= | =Documentation= | ||
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=Tools= | =Tools= | ||
==IR Laser== | ==IR Laser== | ||
Tested. Mirrors are in place, but laser tube has died. | Tested. Mirrors are in place, but laser tube has died. | ||
== | ==Extruders== | ||
In | In progress. Works just like any other 3D printer. Plan on at least two nozzles, one for high-precision (<0.35mm), one for high-speed (>1mm). | ||
==Mill== | ==Mill== | ||
In progress. Standard 120V AC drill, connected to control circuitry by SSR. | In progress. Standard 120V AC drill, connected to control circuitry by SSR. | ||
==Pick And Place== | |||
In Progress. camera system, part feeders, and vacuum based pick up and rotate tool will need to be added. | |||
==VLSI Projection Lithography== | ==VLSI Projection Lithography== | ||
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=Pricing= | =Pricing= | ||
As with other HacDC tools, operators are asked to pay for consumables used only for heavy usage. However, this machine can easily consume | As with other HacDC tools, operators are asked to pay for consumables used only for heavy usage. However, this machine can easily consume a few hundred dollars of filament in one job... | ||
=Safety= | =Safety= | ||
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=Assembly= | =Assembly= | ||
First, attach the makerslide to all of the rail segments. Do this by placing the nut in the t slot (flat side up), sliding the makerslide until the screw hole lines up with the nut, then threading the bolt into the nut. Do not tighten, so that the makerslide slides easily when placing the next bolt/nut pair. | First, attach the makerslide to all of the rail segments. Do this by placing the nut in the t slot (flat side up), sliding the makerslide until the screw hole lines up with the nut, then threading the bolt into the nut. Do not tighten, so that the makerslide slides easily when placing the next bolt/nut pair. | ||
For the rail segments that attach to the optical table, insert a washer between the V grove plate, and the extrusion. | |||
=Upgrades= | =Upgrades= | ||
Revision as of 05:57, 11 January 2016
Multi-tool CNC platform in progress atop the optical table to enable ultra-precise fabrication on a massive scale. Derived from FlexReplicator.
This is the kind of machine one might use to 3D print large herringbone power transmissions for lost PLA casting, or carry out a VLSI production run.
Status
Assembled and operational.
Features
- Approximately 7'x2'x1.5' build area.
- Built on 100W Laser Cutter (tube down ATM).
- Rock-solid, supported by optical table and 40 series extrusions.
- Supports multiple tools and capabilities, starting with 3D printing and Laser Cutting.
- Simultaneous multi-tool use will enhance utility, such as milling down 3D printed layers.
Documentation
- Part of design hosted on github.
- Rest of design hosted at The FossCar Project.
Tools
IR Laser
Tested. Mirrors are in place, but laser tube has died.
Extruders
In progress. Works just like any other 3D printer. Plan on at least two nozzles, one for high-precision (<0.35mm), one for high-speed (>1mm).
Mill
In progress. Standard 120V AC drill, connected to control circuitry by SSR.
Pick And Place
In Progress. camera system, part feeders, and vacuum based pick up and rotate tool will need to be added.
VLSI Projection Lithography
In progress. Modified (ultraviolet) DLP projector and camera mounted to microscope, used for high-resolution patterning. Absolute accuracy (inter-frame) is expected to be ~2um, while relative accuracy (intra-frame) is expected to be <0.5um, scalable down to diffraction-limited performance.
Casting
Direct metal printing thus far is either highly expensive, low-strength, or both. Compromise is to 3D print a plastic (PLA) part, then cast it to metal. Besides low cost, this process can be used to achieve parts traditionally infeasible, like pre-assembled herringbone-gear power transmissions.
Pricing
As with other HacDC tools, operators are asked to pay for consumables used only for heavy usage. However, this machine can easily consume a few hundred dollars of filament in one job...
Safety
Usual safety precautions apply. Additionally, open operation of a Class 4 laser demands eye protection for anyone in the room. Catastrophic retina damage will occur instantly upon viewing the projected spot, which is no less hazardous than direct beam viewing. This is especially true for lasers with a <10um wavelength (ie. non-CO2, eg. ultraviolet).
Assembly
First, attach the makerslide to all of the rail segments. Do this by placing the nut in the t slot (flat side up), sliding the makerslide until the screw hole lines up with the nut, then threading the bolt into the nut. Do not tighten, so that the makerslide slides easily when placing the next bolt/nut pair.
For the rail segments that attach to the optical table, insert a washer between the V grove plate, and the extrusion.
Upgrades
Once the basic platform has been deployed, simple upgrades may be applied if necessary. These may be particularly relevant to edge cases like CNC milling or VLSI patterning. However, these upgrades involve tradeoffs (ie. inertia, friction, cost, etc), and should only be applied upon discovery of a clear requirement.
Relative Accuracy (Vibration)
- Multiple Z-Axis gantries.
- Additional Z-axis actuators.
- Z-axis threaded rod stabilizers.
- Interferometric linear optical encoders.
- Magnetic brakes and micro-actuator stages.
Maximum Force
- Vectran rope timing belt replacements.
- Larger stepper motors.
- Combined X/Y actuators. Threaded rod and pulley.
Structural
- Metal cast replacements for 3D printed brackets (particularly gantry 'boots').
Troubleshooting
When troubleshooting precision errors and planning upgrades, it is helpful to review the most likely causes.
- Inadequate or excessive wheel pressure (check eccentric spacers).
- Poor alignment along axes with multiple drivers.
- Twisting at or near linear motion carriages.
- Backlash at boots joining X and Z axes.
- Separation between highly stiff (table, 40 series extrusions) and less stiff (20 series extrusions) materials.
- Warping of stiff materials (should not ever occur, would imply gross overloading and abuse exceeding several hundred pounds force).
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