(Resubmitted because of again issues x3)
I made a 3D Printer Filament extruder that takes raw ABS pellets and turns them into a roll of filament ready to print!
How it works:
1. Raw pellets are fed through a hopper into the extrusion tube.
2. The pellets are melted down through an auger bit and pushed through a custom CNC milled nozzle
3. The filament passes through two fans to cool it
4. It passes through a diameter sensor which controls the puller speed to keep consistent diameter
5. A gantry aligns the filament on the roll
6. Finally, the spooler rotates and spools the filament
Notes:
Much of this project was completed outside of HackClub, but I completed much of the final assembly in HackClub.
This component was ENTIRELY custom designed (with a few reference models like the electronics) and custom manufactured involving:
• CNC routing on my custom CNC router (PCBs and metal parts)
• Lasercutting (I used a laser cutter I have access to to lasercut all the panels)
• 3D printing (Corner parts, all other parts made on my Voron 2.4)
CAD:
Due to the huge size of the CAD model, I cannot realistically upoad it. However, I will provide a link to view the CAD online.
myhub.autodesk360.com/ue2cd6b4d/g/shares/SH30dd5QT870c25f12fc5767036ad2bc12d9 (may take a little while to load)
Features and Specs
• 3D printed and lasercut custom frame
• RAMPS 1.6 and Arduino Mega based controller
• Stepper motor drive for spooler, gantry, and puller
• Custom LCD display mount using an i2c LCD, with a custom button controller
• Custom motor protection board
• 350w meanwell powersupply
• Custom machined 3d nozzle
• Custom machined heater blocks (4x 40w for 160w max)
• Custom PID heat control with thermal runaway, max/mintemp detection
Other notes:
This design is still not entirely done. Like almost all projects, it will never be perfect, and improvement is always an option. Some of the ways this can be improved:
1. The reliability of the extrusion is not ideal and needs more testing
2. The extrusion code needs tuning and a little further development
3. I would have preferred matte black acrylic which would have looked better, but was unable to source it for a reasonable cost
4. I would have liked to have added lighting, and may do so in the future
Software:
This project uses much software that I custom developed. This can be viewed on the github page (it is not final and is a little messy)
github.com/LordBBQ/ReFil
(Resubmitted because of again issues)
I made a 3D Printer Filament extruder that takes raw ABS pellets and turns them into a roll of filament ready to print!
How it works:
1. Raw pellets are fed through a hopper into the extrusion tube.
2. The pellets are melted down through an auger bit and pushed through a custom CNC milled nozzle
3. The filament passes through two fans to cool it
4. It passes through a diameter sensor which controls the puller speed to keep consistent diameter
5. A gantry aligns the filament on the roll
6. Finally, the spooler rotates and spools the filament
Notes:
Much of this project was completed outside of HackClub, but I completed much of the final assembly in HackClub.
This component was ENTIRELY custom designed (with a few reference models like the electronics) and custom manufactured involving:
• CNC routing on my custom CNC router (PCBs and metal parts)
• Lasercutting (I used a laser cutter I have access to to lasercut all the panels)
• 3D printing (Corner parts, all other parts made on my Voron 2.4)
CAD:
Due to the huge size of the CAD model, I cannot realistically upoad it. However, I will provide a link to view the CAD online.
myhub.autodesk360.com/ue2cd6b4d/g/shares/SH30dd5QT870c25f12fc5767036ad2bc12d9 (may take a little while to load)
Features and Specs
• 3D printed and lasercut custom frame
• RAMPS 1.6 and Arduino Mega based controller
• Stepper motor drive for spooler, gantry, and puller
• Custom LCD display mount using an i2c LCD, with a custom button controller
• Custom motor protection board
• 350w meanwell powersupply
• Custom machined 3d nozzle
• Custom machined heater blocks (4x 40w for 160w max)
• Custom PID heat control with thermal runaway, max/mintemp detection
Other notes:
This design is still not entirely done. Like almost all projects, it will never be perfect, and improvement is always an option. Some of the ways this can be improved:
1. The reliability of the extrusion is not ideal and needs more testing
2. The extrusion code needs tuning and a little further development
3. I would have preferred matte black acrylic which would have looked better, but was unable to source it for a reasonable cost
4. I would have liked to have added lighting, and may do so in the future
Software:
This project uses much software that I custom developed. This can be viewed on the github page (it is not final and is a little messy)
github.com/LordBBQ/ReFil
(Resubmitted because of hakkun issues)
I made a 3D Printer Filament extruder that takes raw ABS pellets and turns them into a roll of filament ready to print!
How it works:
1. Raw pellets are fed through a hopper into the extrusion tube.
2. The pellets are melted down through an auger bit and pushed through a custom CNC milled nozzle
3. The filament passes through two fans to cool it
4. It passes through a diameter sensor which controls the puller speed to keep consistent diameter
5. A gantry aligns the filament on the roll
6. Finally, the spooler rotates and spools the filament
Notes:
Much of this project was completed outside of HackClub, but I completed much of the final assembly in HackClub.
This component was ENTIRELY custom designed (with a few reference models like the electronics) and custom manufactured involving:
• CNC routing on my custom CNC router (PCBs and metal parts)
• Lasercutting (I used a laser cutter I have access to to lasercut all the panels)
• 3D printing (Corner parts, all other parts made on my Voron 2.4)
CAD:
Due to the huge size of the CAD model, I cannot realistically upoad it. However, I will provide a link to view the CAD online.
myhub.autodesk360.com/ue2cd6b4d/g/shares/SH30dd5QT870c25f12fc5767036ad2bc12d9 (may take a little while to load)
Features and Specs
• 3D printed and lasercut custom frame
• RAMPS 1.6 and Arduino Mega based controller
• Stepper motor drive for spooler, gantry, and puller
• Custom LCD display mount using an i2c LCD, with a custom button controller
• Custom motor protection board
• 350w meanwell powersupply
• Custom machined 3d nozzle
• Custom machined heater blocks (4x 40w for 160w max)
• Custom PID heat control with thermal runaway, max/mintemp detection
Other notes:
This design is still not entirely done. Like almost all projects, it will never be perfect, and improvement is always an option. Some of the ways this can be improved:
1. The reliability of the extrusion is not ideal and needs more testing
2. The extrusion code needs tuning and a little further development
3. I would have preferred matte black acrylic which would have looked better, but was unable to source it for a reasonable cost
4. I would have liked to have added lighting, and may do so in the future
Software:
This project uses much software that I custom developed. This can be viewed on the github page (it is not final and is a little messy)
github.com/LordBBQ/ReFilNOTE 2:
These sessions were submitted before the requirement for two scraps per ticket so many only have one.
REPOST: (Scrappy didn't respond)
Smart home model with 3D printed brackets and custom WLED controller.
I started this prior to joining Hack Club, but the premise is to create a model of a smart home to use for testing and demonstration purposes. I used a professionally printed royalty free vector with 3d printed "walls" which have NeoPixel LEDs in them. The light onto the home like smart lights would in a real house.
I also fitted a sun/moon display which I also 3D printed and designed which shows the time of day. It is connected to a custom controller and runs a script which cycles through all the available scenes on HomeAssistant, for demonstration purposes.
I also made a custom wireless light switch using a Shelly i4 DC.
CAD files: github.com/LordBBQ/HomeView
Vector file: www.freepik.com/vectors/cross-section-house (NOT MINE)
It all communicates to a Pi 5 running OpenWRT with HomeAssistant embedded via Docker. The Pi acts as it's own AP for the devices to connect to.
LEDs show up terribly on camera because of the super glossy paper.
Features:
Dual zone Heaters
16 RGBW LEDs
ESP32s2 based WLED wifi controller
4 way wifi Shelly i4 DC switch (custom printed parts)
Videos:
youtu.be/L0GVKQ5so5Ywww.youtube.com/watch?v=Kw1_TusPRZI
