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Rostock Mini 3D Printer Author: Ríona Corrigan Supervisor Rostock Mini 3D Printer 2013 University of Ulster School of Engineering MEng Engineering Final Year Report Title: Rostock Mini 3D Printer Author: Ríona Corrigan Supervisor: Mr McCrum Year: 2012/2013 i Ríona Corrigan B00439354 Rostock Mini 3D Printer 2013 Project Specification In recent years Johann Rocholl designed and developed the Rostock 3D printer, which is a delta 3D printer. Brian Evans followed by designing and developing the Rostock Mini. This smaller printer was designed to have a smaller build volume which would allow for a smaller, more compact version of the delta RepRap design, in other words, a domestic 3D printer for your desktop. My goal will be to build my own Rostock Mini and I will observe my results, and research improvements for the printer, all the while, developing an in-depth knowledge of robotics and CNC programming. This will provide me with the opportunity to integrate my knowledge of mechanics and electronics and software to work towards a working, operable outcome. ii Ríona Corrigan B00439354 Rostock Mini 3D Printer 2013 Acknowledgements I would like to convey my thanks to my supervisor, Mr McCrum, for his support, guidance, and time contributing to the completion of this project. I extend my thanks to his colleague, Mr Henshaw, who helped me to “learn by doing”, and without whom, completion of this project would not have been possible. Thanks too, to Dr Irvine, without whom this project would never have passed the planning stage. I wish to take this opportunity to thank the team of technicians and engineers in Block 6, particularly, Jim, Graeme, Gary, Paul, and Roy. My thanks also, to Ian Todd, and Wilf Gilmore, who always ensured that I left the premises, every evening, at a reasonable hour. I will always be extremely grateful for the day that I met Dr Frank Owens. Dr Owens has never failed to offer his help and advice. He has given unstintingly of his time, and his guidance was always unsurpassed. I will forever remember him with gratitude and regard. Thanks to my family, and friends. iii Ríona Corrigan B00439354 Rostock Mini 3D Printer 2013 Abstract It has been predicted that, in the not too far off future, there will be 3D printers in every household. The materials used in these domestic printers can range from plastics, metals, and food-stuffs. The uses for these printers are potentially endless. This project aims to explore the assembly and commissioning of a 3D printer, that of the Delta robotic design, it’s working technologies, and the possibility of taking the concept further. Since the Rostock Mini is still merely at its prototype stages, the task was given to build and programme a version of the Rostock Mini model. This would aim to identify the components and technology required for building a replicator printer. It would involve the integration of mechanics and electronics and software, and help towards further development of one’s knowledge of technology, in automation, robotics, and software development. iv Ríona Corrigan B00439354 Rostock Mini 3D Printer 2013 Student Declaration of Ownership I declare that this is all my own work and does not contain unreferenced material copied from any other source. I have read the University’s policy on plagiarism and understand the definition of plagiarism. If it is shown that material has been plagiarised, or I have otherwise attempted to obtain an unfair advantage for myself or others, I understand that I may face sanctions in accordance with the policies and procedures of the University. A mark of zero may be awarded and the reason for that mark will be recorded on my file. _________________ Ríona Corrigan Jordanstown, 24.05.2013 v Ríona Corrigan B00439354 Rostock Mini 3D Printer 2013 Contents Project Specification .................................................................................................................. ii Acknowledgements ................................................................................................................... iii Abstract ..................................................................................................................................... iv Student Declaration of Ownership ............................................................................................ v Chapter 1: Introduction ........................................................................................................... 10 The project ........................................................................................................................... 10 Aims and objectives ............................................................................................................. 10 Core Objectives: ................................................................................................................... 10 Chapter 2: Reprap 3D Printing ................................................................................................. 11 An Introduction to 3D Printing ............................................................................................. 11 The Basic Operation of 3D printing .................................................................................. 14 An Introduction to Reprap ................................................................................................... 15 Darwin .................................................................................................................................. 16 Mendel ................................................................................................................................. 18 Mendel Prusa ....................................................................................................................... 20 Huxley ................................................................................................................................... 21 Other Developments and 3D printing devices ..................................................................... 22 The Ultimaker ................................................................................................................... 23 The Makerbot Replicator 2X ............................................................................................. 23 Chapter 3: Rostock 3D Printer ................................................................................................. 25 The Rostock and Rostock Mini 3D printer ............................................................................ 25 Basic Dimensions and Other Information ........................................................................ 25 The End-effector ............................................................................................................... 27 Accuracy ............................................................................................................................ 27 Cost ................................................................................................................................... 28 Advantages of the Rostock ................................................................................................... 29 Chapter 4: Enabling Technologies............................................................................................ 31 Hardware .............................................................................................................................. 33 vi Ríona Corrigan B00439354 Rostock Mini 3D Printer 2013 Electronics ............................................................................................................................ 34 Sanguinololu Electronics ................................................................................................... 34 Sanguinololu Board Schematic Diagram .......................................................................... 35 Sanguinololu Board Schematic ......................................................................................... 36 Stepper Motors and Drivers ............................................................................................. 36 The End-stops ....................................................................................................................... 38 The Extruder ......................................................................................................................... 39 Software ............................................................................................................................... 39 Bootloader ........................................................................................................................ 40 Firmware ........................................................................................................................... 40 Host software ................................................................................................................... 41 Replication Material ............................................................................................................. 42 Integration of the enabling technologies ............................................................................. 44 Commissioning (Software) ................................................................................................... 45 Calibration ............................................................................................................................ 46 Chapter 5 – Extruder Information ..........................................................................................
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