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RailCore II corexy

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My Duet controlled machine
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  • undefined
    kraegar
    last edited by 27 Jun 2017, 18:44

    This post will be the "official" home of Railcore II during the build & Documentation phase. Any Feedback is welcome!

    A summary of Railcore II
    https://www.thingiverse.com/thing:2407174


    (This is Steve's Prototype build of Railcore II)


    The latest Render from Fusion360

    RailcoreII is a Core-XY based Reprap 3d printer designed by J. Steve White & Tony Akens. The initial idea to collaborate on a printer started in the #RepRap IRC channel, and centered on some common goals we both had in mind for a new printer design.

    • Core-XY motion.

    • All Linear rails for movement

    • Space & Cost Efficient, enclosable frame

    • Key components being printable, or able to be milled

    • Flexibility and Scalability in the design

    • A professional looking printer

    • Self Sourced and Easily customizable

    Steve had previously built the “railcore”, the “alpha” version of this printer. We took what he’d learned from it, and began the design on the new printer. All design work was done in Fusion360.
    As we progressed, we decided to “publish” this printer in an open, documented format for others to build as well.

    The frame is designed to be 1515 aluminum extrusion. This was a space efficient choice, and it makes building the printer easy, as standard M3 hardware works like a T-Nut, fitting into the extrusion nicely. To add rigidity, we use melamine sides to stiffen the frame. (These can be cut out of any material you prefer, including plywood, acrylic, aluminum, etc). The total cost for the actual frame components (Extrusion, corner cubes, and sides) is roughly $100.

    From there, some key design decisions were to make the build volume a 250mm cube. This kept the total printer size to what we considered reasonable. The design is easily expandable to 300mm cubed. Some notable aspects of the design: dual leadscrew Z-Axis with a belt drive between them, Stacked idlers duo-planar belt path. The electronics in the design are the Duet (Wifi or Ethernet), 24v PSU, 0.9 degree steppers. We used an E3D v6 for the design, as it’s the most common hotend at this time. Support for other hotends will be forthcoming (needing only a different Y carriage). Semi-Direct drive or full bowden is supported.

    A special thanks to Filastruder, Duet3d, E3D, SeeMeCNC, and 713Maker for supporting the project.

    Co-Creator of the RailcoreII CoreXY printer
    https://www.thingiverse.com/thing:2407174

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    • undefined
      kraegar
      last edited by 27 Jun 2017, 18:47

      Current Project Status: Steve's Railcore II prototype is printing its own parts and upgrades. Currently he's working on the PanelDue & a Pi Cam mount. I'm about to begin assembly on the documentation build, which should be a "near final" revision using the parts Steve has implemented in his prototype. The documentation build itself will hopefully take about a week to complete, with the documentation being updated as I make progress.

      Co-Creator of the RailcoreII CoreXY printer
      https://www.thingiverse.com/thing:2407174

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      • undefined
        elmoret
        last edited by 27 Jun 2017, 19:00

        Cool, looking forward to it!

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        • undefined
          raykholo
          last edited by 27 Jun 2017, 19:17

          Woohoo, this is looking good.

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          • undefined
            kraegar
            last edited by 29 Jun 2017, 01:53

            Last night I sunk the brass inserts into the printed parts, drilled out all the holes, and completed all the "Pre-Build" items, including getting the last printed parts done.

            Here's a pic of all the printed parts together.

            http://imgur.com/fRDCgpv

            Tonight I built the outer frame, and documented it. Went together well, honestly documenting took more time than building.

            Here's a picture of the "Day 2" progress.
            http://imgur.com/d56Lkdy

            I had to stop because of a small issue with the printed yokes - the antibacklash nuts I used (from the BOM) have a 16mm hole spacing, the yoke has a 22mm spacing. Quick change and I'll reprint tomorrow and get back to building.

            Co-Creator of the RailcoreII CoreXY printer
            https://www.thingiverse.com/thing:2407174

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            • undefined
              kraegar
              last edited by 30 Jun 2017, 03:01

              Tonight's progress updates.

              http://imgur.com/tVBTWp3

              Z-axis installed. Minor reprints on the assembly tools for lining up the vertical Z extrusions. Documented and photographed the install of the leadscrews, which took a while. It all went together fairly easily (other than some headache with a bearing that was a tad too snug on a leadscrew).

              Tomorrow - sides!

              Co-Creator of the RailcoreII CoreXY printer
              https://www.thingiverse.com/thing:2407174

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              • undefined
                kraegar
                last edited by 7 Jan 2017, 13:50 1 Jul 2017, 13:48

                Last night I got a lot more than sides done. Idler on, and the Y rail on. Starting to look like a real printer.

                Side note, with the sides on, this thing is super solid. There's no way it's flexing or having stability issues.

                Some minor corrections and edits to parts, and some little missing bits of hardware to add the the BOM. The assembly is going well, though. It's a fairly easy printer to put together, really.

                Edit: finally got the right pictures linked!

                Co-Creator of the RailcoreII CoreXY printer
                https://www.thingiverse.com/thing:2407174

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                • undefined
                  kraegar
                  last edited by 3 Jul 2017, 12:31

                  Current status:
                  Some minor delays prevented me from completing it yesterday, but it's close. Bed & Hotend are on. Endstops are in place.

                  Only thing left to do is to mount the electronics, wire it, and power it on.

                  Co-Creator of the RailcoreII CoreXY printer
                  https://www.thingiverse.com/thing:2407174

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                  • undefined
                    T3P3Tony administrators
                    last edited by 3 Jul 2017, 13:07

                    Looking good!

                    www.duet3d.com

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                    • undefined
                      kraegar
                      last edited by 7 Apr 2017, 22:01 4 Jul 2017, 22:01

                      Today's Status:

                      Co-Creator of the RailcoreII CoreXY printer
                      https://www.thingiverse.com/thing:2407174

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                      • undefined
                        Whitewolf
                        last edited by 7 Apr 2017, 22:23 4 Jul 2017, 22:22

                        Beautiful! I am curios to know what the best achievable speed while maintaining quality is.

                        Exploring the universe wherever the tech blows

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                        • undefined
                          kraegar
                          last edited by 7 May 2017, 12:20 5 Jul 2017, 12:19

                          So, I'm printing. I still have some tidying up to do on the electronics (need to box up that side once I'm sure the wiring is all settled). Need to wrap the wires up, etc. Print a paneldue enclosure and attach it. Little miscellaneous items like that. There's a slight bit of tweaking to be done to get the plane of the bed completely flat. It's close, but it can be better.

                          So the click of "print" on the first test, a 20mmx20x10 cube, gave a very nice result with mesurements 20.04 x 19.98 x 9.99.

                          Here's the second print, the traditional benchy.


                          I've printed enough of them to say I can look at this one and not see anything that stands out as needing drastic improvement. There was no appreciable stringing - just 3 or 4 fine wisps. The surface is even, the cooling was excellent (the line of the bow shows zero sights of any curling) and all the thin walls meet nicely. That was printed at 75mm/s. Edit: the last pic seems to show a layer or two that bulge in the bottom right. They don't in person - I checked after I saw them in the pic. I think it's a trick of the filament and the lighting)

                          Co-Creator of the RailcoreII CoreXY printer
                          https://www.thingiverse.com/thing:2407174

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                          • undefined
                            kraegar
                            last edited by 5 Jul 2017, 12:42

                            I did fight with Z motion for a while yesterday, was really weird. I'd get double, half, no movement, or even movement in the opposite direction from sending a simple G1 Z10 / G1 Z-10. Reflashing the firmware resolved that one.

                            Co-Creator of the RailcoreII CoreXY printer
                            https://www.thingiverse.com/thing:2407174

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                            • undefined
                              jstevewhite
                              last edited by 5 Jul 2017, 14:36

                              @Whitewolf:

                              Beautiful! I am curios to know what the best achievable speed while maintaining quality is.

                              Kraegar printed the benchy at 75mm/s; I've gone as high as 90mm/s with .4 nozzle at lower layer heights with only slight ringing. Kraegar's build seems to be performing a bit better than my prototype "alpha" model, so we'll have to wait for his high-speed tests. 😄

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                              • undefined
                                kraegar
                                last edited by 7 Jun 2017, 14:02 6 Jul 2017, 12:52

                                Noticing some variation in the IR probe trigger heights across the bed. Trying to figure out what's causing that - square printers are new to me so there's some learning curve there. I like to chase perfection on these things. Everything's within .1mm across the bed currently, but I'd like to get that down around 0.1, the oddball trigger height variation is making it tough, though.

                                Co-Creator of the RailcoreII CoreXY printer
                                https://www.thingiverse.com/thing:2407174

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                                • undefined
                                  Whitewolf
                                  last edited by 6 Jul 2017, 14:50

                                  looking good

                                  Exploring the universe wherever the tech blows

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                                  • undefined
                                    kraegar
                                    last edited by 17 Jul 2017, 12:19

                                    Current status: Everything is done on my build. Tested with a BLTouch, and will be tinkering with a piezo just to try one on it (love it on my delta). I need to work on the documentation, and a couple STL's on Thingiverse. I have a ton of photos of the build to process for the documentation.

                                    The great news: this thing prints fantastically. Essentially zero problems with it since the build was completed.

                                    Here's a print from last night.




                                    Co-Creator of the RailcoreII CoreXY printer
                                    https://www.thingiverse.com/thing:2407174

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                                    • undefined
                                      T3P3Tony administrators
                                      last edited by 17 Jul 2017, 18:57

                                      That is a great looking printer and print!

                                      www.duet3d.com

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                                      • deckingmanundefined
                                        deckingman
                                        last edited by 17 Jul 2017, 18:59

                                        Yes, very impressive!

                                        Ian
                                        https://somei3deas.wordpress.com/
                                        https://www.youtube.com/@deckingman

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                                        • undefined
                                          kraegar
                                          last edited by 20 Jul 2017, 13:48

                                          Thanks guys. Spent a couple days out of town for work. I hope to put some time in on the documentation this weekend.

                                          Co-Creator of the RailcoreII CoreXY printer
                                          https://www.thingiverse.com/thing:2407174

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