I’ve been trying to run parts to get a better feeling on what the FDM1650 can/can’t do. I made up a platter of parts for a Mendel Extruder back on 4/13. I hadn’t checked how much of the MG-47 was left, and I ran out of filament early in the run. Sadly, I wasn’t checking the ‘cams, so the machine cooked for more than 22 hours (31 hour run) —rrr… The photo of the partial run shows the parts were looking pretty good, but I doubt the gears would mesh to good with the Y Axis backlash.
This pointed out two things I need to learn. The first is ‘how to recover’ from this error without throwing away partially completed parts. The second is ‘how to NOT cook the heads’! It took several hours of trying to get the old P400 I had on hand to load and spurt out. Then once loaded, Insight didn’t seem to to want to restart the run. Perhaps there was something I needed to do to save a restore point?
I needed to make some wire spool holders to organize a workbench a bit. I ran these using the old P400 and sliced with Insight using sparse settings. They were tall so the build took forever, and then some. All done, there were a few hairs but not too bad:
When I went to remove the parts from the foam, I grabbed one of the uprights and tried to pop it off. Instead of seperating, the joint to the base cracked. I guess I need to redesign a bit to strengthen that joint, and quit trying that technique to remove parts. Another thing I noticed is the Stratasys P400 really grips the support compared to the MG-47 I had been running. I still haven’t finished getting it all off!
I’ve only got ~70 wraps of MG-47 on Stratasys spools, so I need to get started on a respooler setup that doesn’t span two lathes — also, needs a much lower RPM & a way to lay the filaments evenly. The 70 wraps I have left is what wouln’t fit on a spool with a random lay. I used to have an old coil winder I had hoped to duplicate, enlarge, and add a motor — of course I haven’t been able to find where I stored it (if I still have it?), but I did come across a PDF for building a Gingerly Coil Winder. I figure to mesh some of the coil winder features with the respooler HaveBlue found on Thingiverse. Gingerly used a adjustable right-angle drive to drive a circular cam to move a rod having a wire guide across the spool. I’d need a way to get pulses out of each rev of the spool to drive a stepper (that I’ll mount the cam on), so I modeled up a couple of gears to see how they might work:
As with the spool holders, the support is real hard to remove with the P400 model material. The smaller sector wheel, I’m going to try with an optical sensor, and the larger I’m going to try a mechanical pulse generator with a microswitch. Both are going to take a little playing.
Now for a cam. An offset circle is not going to be linear (0.070″/rev), so I designed up a heart shaped cam that will do that across the 3 1/2″, and return:
Somehow, these pieces need to fit together with an flea market air drive motor — this guy goes REAL SLOOOOOW, but noisy like all air drives. Hopefully, should work pretty well:
So, some bench work ahead to see how this all come together….