Now that is customer support! Awesome!

Daniel I am glad I stumbled on your thread. What batch number were you?

I have to say I disagree with a majority of your review from what I have experienced (Sorry).

Quick summary of my experience:

I was Batch 4, for multiple reasons (Cheaper, and They worked out a lot of kinks between Batches 1-3) and I must say I was pleasantly surprised when mine arrived. Packaging was minimal unfortunately one mine, BUT I do packaging design at my workplace along side product design, and I felt a majority of the critical components were protected and fixtured enough for shipping. No real negatives there.

Out of the box I heard a rattling and found a screw had come loose on the inside holding the Duet Maestro to the printer frame. Easy fix.

As for the frame rigidity, I feel you got a bad unit or something because aside from me torquing the screws tighter for a snug fit, my frame is very solid. It wasn't perfectly square but didn't expect it to be, so I went about the assembly with a small square and straightened what I could, and re-adjusted all the cam bolts. Each wheel mates as it should with the extrusions, and no sheet metal parts are bent. As an Ender 3 Z-axis design (first time seeing one) its pretty solid. Very little slop when pulling only on the side without the leadscrew.

The Extruder is... interesting. Still trying to get it to work perfectly but only tried to print PETG on it so far. Feeding issues are hit and miss and random, which is very annoying. Still need to bite the bullet and order some PLA to really have fun with it and see if its just not meant to deal with PETG.

All in all, as far as a Kickstarter printer goes I am happy with it.

For the Maestro portion, it has performed flawless. No issues that have caused a concern, aside from some heater faults. Its actually nice to see some organization inside of the Systems tab. My CoreXY is a mess in comparison.

@fcwilt said in New CoreXY 400x400x560mm Build in Progress:

@fickert said in New CoreXY 400x400x560mm Build in Progress:

I haven't had the chance to check the flatness on our granite block at work. Will look into that tomorrow.

That would be interesting.

Frederick

Just an update Frederick,

was able to check the flatness of the plate on our granite. About the flattest possible surface to check on (hence it was 30k for us to get made) and attached are my results with our feeler gauges.

from my findings, it looks like the flatness tolerance is between 0.10 - 0.15mm (0.10mm was slightly loose, and 0.15mm was snug) from each furthest corner. Considering thats spanning over 415mm square, I am very pleased with this tolerance. I am curious how close a sheet of glass would be to this.

Anywho, this helps me relieve that this is pretty darn flat

Hi guys,

So our development engineer has been tasked with adding a dispenser to our Roll2Roll line. Being experienced with hobbiest motion control outside of PLC he asked for my help. (I am not super familiar with PLC, neither is the engineer, so if were barking up the wrong tree please let us know).

In an essence, we will be adding a dispenser to travel across the Roll2Roll web (web direction will be -X, +X dispenser direction will be -Y, +Y), but we want to be able to link the dispenser speed with the line speed to assure the speed and dispensing rate will be adjusted to speed changes of the Roll2Roll line.

Our initial thoughts are to use Labview, but he is saying the stepper motor control incorporation is difficult to setup. Additionally I introduced a Duet3 into our large testing Cartesian robot so adding another seems tempting after I showed the ease of use and the quality of the board is.

Sorry for the rambling. To summarize, does this seem possible? Requirements we have found are:

• Control a single axis direction with a dispenser (Should work out the same as a CNC motion and spindle speed control for dispensing rate?)
• Take encoder information from Roll2Roll line, and adapt motion speed and dispensing rate.
• Expandable to possibly add an axis for a full X,Y direction.

Any suggestions would be greatly appreciated.

Thanks

One thing I still really would like to do is mill and tap the joints at the ends and cut 45 degree 100-150mm extrusions for the corners.

So as the title states I am in the works of building a design I have been working on for the past few months.

I first want to say I am typing this on a tablet so please bear with me if I have grammar errors.

Anywho, the start of this build was to convert my FT-5 to a corexy system but no design publically released addressed the issues I see in most corexy designs, Rigidity.

I also HATE the build plate platform design on the FT-5. Linear rods and bearings are used to keep it straight and flat, but fail doing so, as a matter of fact, I can tilt the bed with just light pressure on either the front or rear of the bed.

Lastly, I wanted a larger build area. 300 x 300 x 400 isn't enough, escpecially since the realistic build area I have found is 280 x 280mm.

The FT-5 did it right with using the mgn linear rails, and I am carrying that over to this design as well.

So Goals for this build:

• Rigidity: Idler carriages and idler posts for the corexy system need to be solid. Will be solved with using aluminum square tubing and milled to size.

• Lightweight: I want to create some inovation by making the gantry the lightest possible while being direct drive. Additionally, the idler carriages to also be light by using aluminum.

• Bulletproof Build Platform: Having an unlevel build plate regardless of a BLTouch, is a pain. Aside from being level the build plate NEEDS to be repeatable.

• Build Area: I wanted to get as close as possible to a TRUE 400mm x 400mm square size with at least a 500mm build height.

So to solve a these issues:

• Rigidity: A lot of factors play into the rigidity of the design. One big factor is the aluminum tubing. Others are:

  1. Aluminum is always going to beat any printed part in rigidity and weight.

  2. Aluminumsquare tube will support the idler shafts for the bearings on both sides. A lot of designs only support the bearing shaft by one side, that can result in slop in belt tension during directional change.
     

  3. Any printed part will be made from Carbon Fiber PC, which is a very rigid material; if you can print PC I highly recommend it for builds over ABS, PETG, Etc.
     

  4. The frame is pretty similar to the FT-5, there are a few more extrusions but I think it will be plenty study, especially with using 90 degree cast aluminum braces and likely external braces.

• Idler Bearing Size: I stumbled across an article from a builder that had a direct drive system printing at 150mm/s and higher https://drmrehorst.blogspot.com/2017/07/ummd-corexy-mechanism.html and he swore by using 608 bearings (dia of 22mm was optimal for skewing of the position of the head or something) so I wanted these to be used in the design.
  *Can't remember now off the top of my head will get the link and post when I get to work tomorrow.

• Lightweight: When I say lightweight I mainly mean mainly the gantry, carriage idlers, and x-axis.

  1. Gantry: I am swapping to a nema 14 round stepper and a single 4010 blower fan (may opt for 2 fans, will test cooling after it is assembled), and the stepper motor alone shaves 100g from the standard nema 17 pancake stepper motor for the titan aero.
     
  2. I opted for a MGN9N rail for the x-axis. This shaves off a fair amount of weight to throw back and forth on the y-axis. I do have concern of harmonics on the rail at high speeds but there isn't a really good way to check this until its up and running.[link text](link url)

• Bulletproof Build Platform: I mentioned the FT-5 build platform in my opinion is garbage. There are quite a few key features in my build plate design that I feel will make this rock solid:

  1. The base will be made of 2020 aluminum extrusion with 90 degree cast aluminum corner braces and Carbon Fiber PC braces for flatness and rigidity.
  2. Linear motion will be guided by two 600mm MGN 12 rails, which GREATLY reduce the slop the stock bed has in the FT-5.
     The photo below does not have the lead screws in yet but you can see the three supports off the bed platform.
     
  3. There will be 3 Leadscrews to fully fix this build plane, and these will all be tied to a single stepper motor.
  4. The build plate I splurged on a bit. I ended up buying a 1/4in thick 6061 aluminum plate measuring 415mm x 415mm. The plate has been ground with a flatness tolerance of +- 0.38mm. Should be pretty good even if I decide to not use glass.

• Build Area: The build area was a huge "Gotta have" thing for this build to help drive keeping everything to be at the absolute maxed position to keep clear from the gantry. My main focus like I stated was the square flat area of 400mm x 400mm, while having a direct drive extruder. To achieve this, I eliminated the BL Touch and will be using stall homing (on all axis actually) as well as a change in stepper motor. The round Nema 14 stepper motor's lightweight is one large positive, but its form factor was the other. The total footprint of the nema14 stepper and the 4010 fan are smaller in depth than the nema 17 pancake stepper, and still in the same 40mm x 40mm form factor.
  

Electronics: Obviously this will be using the Duet Wifi, but additionaly it will have all the following:

• Controller: Duet Wifi

• PSU: MeanWell SE24 600Watt

• Stepper Motors: Standard nema17 stepper motors from the FT-5

• Heat Bed: 120V AC 1000W 400mm x 400mm silcone bed heater controlled by a SSR with heatsink

• Extruder: E3D Titan Aero; not sure if I will be using the volcano or v6 hotend yet.

Still to do:

I still have to design a few parts yet, but with my parts coming in the mail and seeing my frame take shape I wanted to start to document the build for others.

@t3p3tony I apologize for the delay.

To answer your questions:

1. Exactly

2. Sort of, we prefer the Duet to completely manipulate the gcode it has been given by using the encoder sensor to as closed loop feedback for the x-axis. The Duet in theory will always have the X-axis in motion (or the way we want to manipulate it to see) since the R2R line is continuous.
   My thought was the gantry can travel to Y0 (home) and Set X0 with a command before starting the operation. Then it would just be a rinse and repeat operation. A better comparison is to how the belt style 3D printers operate, just not at a 45 degree angle.

3. The dispenser for the time being I believe is pretty crude, in that its all manual adjustments. Talking with the development engineer, the speeds of the line will vary, but by small margins and as of now it wouldn't be that big of an effect. If dispensing volume and flow become of concern, we will upgrade to a newer system.

4. Yes but this is not the important aspect as of now, but something to keep in mind.

I should clarify, if looking directly down on the R2R web in a 2D space, the Y-axis will be at an angle to the web direction, not perpendicular. This kinematic setup is a setup we have used previously in testing with manual control, we're simply trying to put a controller on it and manipulate it via a program. If you have suggestions for this as well I am all ears.

As for firmware, would it not be possible to remap inputs as necessary? Or do you mean in regards to the kinematics being unique?

Encoder = Duet "X-axis"
Y-axis = Duet Y-axis
Dispenser Flow Rate = Duet Extruder Flow Rate (use stepper driver input as Dispenser input?)

@t3p3tony I believe there isn't an encoder on our system as it stands. if it does have one, it is embedded into the PLC system that it runs off of. I assume we'd not want to tap into that.

So which ever type of aftermarket encoder that is best suited with Duet is ultimately what we'd want to link to the speed and dispensing rate.

Hi guys,

So our development engineer has been tasked with adding a dispenser to our Roll2Roll line. Being experienced with hobbiest motion control outside of PLC he asked for my help. (I am not super familiar with PLC, neither is the engineer, so if were barking up the wrong tree please let us know).

In an essence, we will be adding a dispenser to travel across the Roll2Roll web (web direction will be -X, +X dispenser direction will be -Y, +Y), but we want to be able to link the dispenser speed with the line speed to assure the speed and dispensing rate will be adjusted to speed changes of the Roll2Roll line.

Our initial thoughts are to use Labview, but he is saying the stepper motor control incorporation is difficult to setup. Additionally I introduced a Duet3 into our large testing Cartesian robot so adding another seems tempting after I showed the ease of use and the quality of the board is.

Sorry for the rambling. To summarize, does this seem possible? Requirements we have found are:

• Control a single axis direction with a dispenser (Should work out the same as a CNC motion and spindle speed control for dispensing rate?)
• Take encoder information from Roll2Roll line, and adapt motion speed and dispensing rate.
• Expandable to possibly add an axis for a full X,Y direction.

Any suggestions would be greatly appreciated.

Thanks

@phaedrux buck converter is wired to fan 2. Simply has the fan 2 output pins wired to the voltage input of the buck converter, and I calibrated the buck converter to step down 24V to 12V on my bench supply before installing it. The fan on fan 2 works as intended.

I am likely going to chalk it up to a bad mosfet. Luckily I should have a spare or two from an older duet board I fried a while ago.

@phaedrux Thanks for the look at the mosfet. Probably could have started there.

Mosfets appear intact though. Any other components to check? Like I said there is a small hum when the fan is activated, so I believe the mosfet is switching, maybe where ever the power is passing through to the mosfet? Sorry not super familiar with board electronics but can diagnose and identify components I have some guidance on where to look.

So I am very confused on what happened.

Setup:

Duet 2 Wifi via 24V
Fan 0 = Part Cooling fan
Fan 1 = Hotend Fan; enabled when hotend is above 45C
Fan 2 = Enclosure Fan; when MCU is above 45C, when Stepper warning at 60C

config.g fan profile:
; Fans
M950 F0 C"fan0" Q500 ; create fan 0 on pin fan0 and set its frequency
M106 P0 S0 H-1 ; set fan 0 value. Thermostatic control is turned off
M950 F1 C"fan1" Q500 ; create fan 1 on pin fan1 and set its frequency
M106 P1 S1 H1 T45 ; set fan 1 value. Thermostatic control is turned on
M950 F2 C"fan2" Q500 ; create fan 2 on pin fan2 and set its frequency
M106 P2 X1.0 S2 H100:101:102 T45:65 ; set fan 2 value. Thermostatic control is turned on

To be clear this all worked fine a few days ago and earlier this evening.

The ONLY change I did tonight was to the enclosure fan. It is 12V and I was running it at low 24V until I finally wired in my buck converter tonight. Thats when the fan 0 quit working. In Web Control it shows at 100% but nothing happens. The enclosure fan (fan 2) and hotend fan (fan 1) still operate normally with temperature.

Things I've tried:

• If I unplug the enclosure fan it still does not power up fan 0.
• If I plug in the fan 0 pins into the always on pins, the fans power up just fine.
• When fan 0 is at 100% in Web Control, a small hum can be heard.

Can only a single fan control be fried? This seems very odd to me.

@Veti Thats wild, and very visually informative thank you.

That being said I can't imagine that being too quiet of a setup, but I didn't watch the video with audio here at work.

@Dougal1957 Thanks for the recommendation! How audible is this setup?

So I am redesigning my gantry to be a bowden setup, and am also looking to installing an air pump for a part cooling solution using thin aluminum tubing. I am shooting to lighten the gantry and reduce the footprint to maximize my build plate.

Setup: I am running a 24V PSU but I can step down to 12v and use the ground of the fan pins to control pump speed, correct?

Also I am having a difficult time finding a good "go to" air pump. I am leaning towards a diaphragm pump design since I just got a standard pump in the mail and it is large, and kind of loud. Also it only works on AC so I am returning it regardless. But I am seeing low number of hours (1000-2500hrs life span) can anyone confirm this is all they last? Standard blower fans last 30000 hours from what I have found.

Lastly, I am not sure how much flow is "enough" for a setup like this. What is everyone else using?

I am looking at a few of these, any comments will be greatly appreciated

Pump 1

Pump 2

One thing I still really would like to do is mill and tap the joints at the ends and cut 45 degree 100-150mm extrusions for the corners.