MegaMax was a great 3D printer, but it was time for some changes. He was difficult to transport because the electronics were in a separate housing with many cables to disconnect and reconnect, barely fit through doorways, and required a positively gargantuan enclosure to keep the temperature up to control ABS delamination. Though it hurt to do it, I tore him apart and did a complete redesign/build into a form that is more like what I would have done had I known anything at all about 3D printing when I started building MegaMax.
I reused what I could including a lot of the 8020 extrusions in the frame, the Z axis screw assemblies and drive belt, and the X and Z axis motors.
ball screw drive Y axis with high torque motor- precise but noisy
linear guides in X and Y axes instead of 1/2″ round guide rails and linear bearings
SmoothieBoard controller instead of Arduino/RAMPS
BullDog XL extruder and E3D v6 hot end
RepRapDiscount graphic LCD control panel
narrower frame design without giving up print volume- easier fit through doorways!
polycarbonate panels to enclose the print area yet provide a clear view of the print
electronics in a drawer for easy service and transport and neater appearance
DSP motor drivers and 32V power supplies for X and Y axes
Liberal use of screw terminals to make servicing easier
Modular X and Y axes that can be removed for service and replaced in minutes.
SoM will be making his public debut at the Milwaukee Makerspace very soon…
MegaMax has been and continues to be my main project for the last 2+ years. I am currently working on some upgrades that will make him more Mega and even more Max. The Y axis is being converted from belt drive to screw drive and the round guide rails are being replaced with linear guides and bearing blocks. The X-axis will also get converted to linear guide and bearing block and change from 5mm pitch belt to 2 mm pitch belt drive. I feel confident saying that once these modifications are complete the flaws/errors in prints will be due primarily to the nature of liquid plastic squirting through a nozzle, not positioning system errors.
I recently updated my web site with a sort of historical look at the project, including all the mistakes I’ve made along the way and the often failed attempts at correcting them. Here is the page that shows how it all started, how it has ended up, and where it is going. http://mark.rehorst.com/MegaMax_3D_Printer/index.html
The video shows the last few layers of the calibration cube “printing” at 414% speed (according to my LCD display).
The Bucketworks 3D printing meet-up on 8/12 paid off big-time! Gary Kramlich helped me debug a problem that was preventing me from flashing the firmware on the controller board for the MegaMax 3D printer. After a few tweaks I was able to get it moving.
September 27-28 at Wisconsin State Fair Park, the same weekend as Harvest Fair. Admission is free. Maker Faire Milwaukee's Call for Makers is now open.
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