XLNC 1 - Xtra Large CNC Machine - Mill/3DPrint/Laser etch w/Custom GUI - OBSOLETE - SEE REV 2

thingiverse

REV 2 is being released at the link bellow You can still build REV 1 if you want. REV 2 and 1 share the same XY gantry and Bed parts, but different Z-axis parts. On Rev 1, the bed moves. On Rev 2, the bed is stationary while the Gantry goes up/down. This change was made due to planned implementation of tool changing. LINK TO REV 2:https://www.thingiverse.com/thing:2757069 Follow my project here: https://crunchysann.com/BL/projects/ REV 1 DETAILS This is a project I started a few months ago in an attempt to make a low cost, very large multipurpose CNC machine for my other "Projects". Download the zip files attached to this project page: they contain the STL models. For 25mm OD pipes: Download "25mm_OD.zip" For 38.3mm OD pipes (default configuration used in the videos): Download "38_3mm_OD.zip" Future tool attachments will be added, including the firmware configuration used on the RADDS board. Basic final specs as pictured. Machine footprint: 5'-5'-2.2'(L-W-H) (You can simply use shorter tubing to make a smaller, much more rigid machine) Very large Build Volume when 3D printing: 2.69'-3.48'-1.06'(L-W-H) Very large Area when Milling: 2.69'-3.48'- Tool length (~4" +) Motion: 1.5" (38.3mm) OD. Electrical conduit with User adjustable roller bearings (use better/stiffer tubing if you can get your hands on them). Use metal tubing with smoother surface and thicker walls if you want to expand your machine cutting/ printing area past the specs above. Configurations for 25mm OD and 38.3mm OD pipes have been added. Intended materials supported: Cutting medium to soft grade aluminum and other softer materials Intended usage CNC milling, Laser etching/cutting. 3D printing multiple objects simultaneously Design Features: Table on Z axis: The Table goes up and down on this design. Steel re-enforced GT2 belts: I cheaped out and got 6mm wide belts, but luckily purchased pulleys compatible with 10mm wide belts for future upgraded of belts if needed. Stackable: Many of these machines can be stacked on top of one another Support for toolset expansion: The gantry is made to support Wood routers, Dremels, heavy spindles, 3D printing filament Extruders (1 and up using mounting brackets), and is intended to support future robotic arm addition for hybrid 3D printing and finish milling operations. Enclosure friendly: Since all movements are constrained within the machine's footprint, a full enclosure can be made for it. Stiffer XY gantry: Future tests will be performed to get some actual numbers as to how accurately this particular design can cut hard materials. Since 3D printed parts are not well suited for FEA simulations, do not expect such testing to occur. Adjustable Belt and Bearings: Belt tension is achieve using off the shelf products you can source at your local hardware store. Update 11/6/16: Added Top and Bottom chassis block 3D models including motor mounts. XY carriage is being modified to be stiffer. Update 11/11/16: Added X carriage 3D models including motor mounts. Y carriage is being modified to use similar parts. Update 11/14/16: Updated X and Y carriage 3D models including motor and belt mounts. Update 11/26/16: All 3D STL files scheduled for uploading on 11/27/16: Major changes were made to simplify parts of the machine and make them easier to 3D print. The current motion controller will be RADDS and CNC shield (running in mirror mode for X and Z axes) using DRV8825 Drivers and Repetier firmware and Host. Design to be promoted to Beta thereafter. Update 12/07/16: Design is finalized and parts are being uploaded: Old 3D models deleted Old images deleted New images uploaded (haha I kinda went overboard doing this in my kitchen). Y & X carriage 3D Models included in zip file Remaining 3D Models will be converted to STL, added to the zip file and uploaded daily (kinda very busy atm) Test video uploaded (playing around with how fast I could push the DRV8825 Drivers before stalling the motors). Video youtube link - https://youtu.be/bsenXD5oCrA Final dimensions for my size machine updated. Update 12/14/16: 3D STL file upload completed Please re-download the attached zip file for the latest 3D STL models for this machine. Added images of Makita RT0701C router mount. Next tasks..Add a BOM Update 1/7/17: - Currently testing Gcode compatibility with Repetier Firmware Added images of X-axis pulley supports Changed bed material from wood to more rigid yet still cheap wall mounting plastic (Fastrack) Added STL files for bed clamp sockets (use together with thing 21057) Added STL models for new 20x20mm to Bed (couplers) Modified GRBL Post-Processor from Vectric to work with Repetier Firmware. Successfully Tested Milling tool-chain compatibility (Vectric Aspire [CAD / CAM] --> Repetier Host with CNC extension [CNC GUI] --> Repetier Firmware [0.92] -->RADDS+CNC SHIELDS [Hardware] Added images of initial movement and test cuts Added video of initial test cuts just to test G-code compatibility: https://youtu.be/40uC6aKao1k Update 1/19/17: - Currently test cutting materials -Added video of cutting Wood fixture for aluminum stock: https://youtu.be/x6bRLzgBqbA Update 02/02/17: - Currently test cutting materials Added video of first very conservative cutting of aluminum stock: https://youtu.be/W4KUQvgwvOk Added images of first prototype dust boot Update 02/05/17: - Currently test cutting materials Added video of second test cutting of aluminum stock: https://youtu.be/b2CTbTamWYk Uploaded STL files for 25mm OD and 38.3mm OD pipe configurations. Update 02/07/17: - Major update done to 25 mm design files Updated effective pipe OD from 32mm to 25mm OD Modified belt anchors to keep timing belts parallel along axis. Update 03/12/17: - Eye can finally see without glasses!!! now onto More testing. Finished testing Vectric Aspire Post for Repetier firmware (CNC mode only) Testing HSMWorks (might work with Fusion360 too) Repetier compatible post-processor Started sub-assembly SolidWorks assembly instructions. Update 03/18/17: - Work on XLNC is temporarely halted while I upgrade my Flashforge Creator printers. Link to upgraded parts thing here: http://www.thingiverse.com/thing:2185486 Update 05/7/17: - ALPHA HSMWorks to Repetier/Marlin post-processor uploaded. File name: HSMWorks 3 Axis Repetier_Rev5.CPS Update 06/15/17: - Marking HSMWorks to Repetier/Marlin post-processor as BETA. Update 06/15/17: - Developing custom XLNC control panel plugin for Repetier Host 2.0: Current feature list to implement is: User-selectable machine Mode (CNC, 3D PRINTER, LASER) Remember last Work origin User defined workspaces Return to selected Origin Users can edit and assign different GCODE or scripts to buttons Still deciding on data handling structure since I won't use the registry. Update 08/17/17: - Developing custom XLNC control panel plugin for Repetier Host 2.0: Current features implemented include: User-selectable machine Mode (CNC, 3D PRINTER, LASER) Return to selected Origin Using SQLite Database (for coordinates) back-end and text files (to store User Gcode) for persistent storage. Update 12/14/17: - Developing custom XLNC control panel plugin for Repetier Host 2.0: Current status: Developing event handling scheme. Testing Gcode parsing scheme Update 1/6/18: - Major rework done to machine frame components to optimize print time, strength, and reduce part count. Optimized Frame corner brace design from 4 pieces to 1 piece Optimized Z axis design such that the gantry moves up/down, instead of moving the table up/down. this is done to reduce moving mass and allow heavy objects to be placed on bed. Bed is now stationary Optimized most parts to no longer need washers Changed motor mounting orientation for X/Y axes to reduce strain on belt pulleys. Next steps: Release Alpha version of XLNC control panel as a separate "Thing" Release XLNC 2 as separate "Thing" Add 1st set of assembly videos Note: For 25mm OD configuration, please report any issues you find. I don't have the physical space to build and test that configuration. Print Settings Printer: Flashforge Creator Pro - Simplify 3D Slicer Rafts: Doesn't Matter Supports: Doesn't Matter Resolution: 300 um (0.3 mm) Infill: 5% or more, 4 wall loops (or 1.6mm or more wall, Top, Bottom thickness) Notes: Due to the nature of the machine's design and anticipated usage (Milling metal accurately and very large 3D printing area), parts are designed to make the chassis very stiff. All parts can be printed without supports and will fit standard 5 in x 5 in or bigger print beds. TIPS: Use a cooling fan when printing PLA Use a better material such as PETG for even stronger parts (although this is more expensive) Tip For stronger parts: Before assembling the machine, coat the corner braces that hold your frame together using Smooth-On 3D Epoxy filler. Print parts so that the largest face of each model sits on the print-bed https://www.smooth-on.com/product-line/xtc-3d/ 1-2 coats per part is enough. let dry for at least 24hrs before assembling the machine, otherwise those parts may crack during assembly.