Monthly Archives: July 2015

RepRap Sintron Prusa i3 3D Printer

Just a Couple of random pics from the printer i will be adding a ton more of my projects to the site soon


one of the first 10mm calibration cubes printed at 0.3mm layer height.


Another one of the 10mm calibration cubes printed at 0.2mm layer height this time.


One of two quick brackets for the LCD Controller to replace my quick cardboard cut out stand.


Back Top of 10mm endstop bracket for my 8mm rods FAIL!!! 🙂


Back of 10mm endstop bracket for my 8mm rods FAIL!!! 🙂


Top of 10mm endstop bracket for my 8mm rods FAIL!!! 🙂


Eiffel Tower That started well


Eiffel Tower and got better


But then Cocked its leg


and what looks like some kind of over fill put the finishing touches on this Fail!!! 🙂


The final Eiffel Tower


Some new endstop mounts and another extruder holder just in case this one broke


Close up of new endstop mounts


Close up of MK8 Light extruder holder just in case this one broke


Printing a filament holder using hairspray to stick it to the bed at 90c using 40% honey comb fill.


Slight lifting pf the filament holder using hairspray to stick it to the bed.


Final prints had a few problem like the perimeters not adhering to the in fill so i patched it up with lots of supper glue.


They might be a little wonky but the filament spool holds up nicely on them for now.


MK8 Heavy duty extruder holder, capacitive sensor mount and filament cooling nozzle.


Thes prints still had issues with the perimeter bonding to the infill so i reprinted them once i had tweaked the layer width from 0.35mm to 0.5mm which is working much better.


Top view of the failed prints assembled.


Side view of the failed prints assembled.


Front view of the failed prints assembled.

TV Stand CNC

This build was my first attempt at a 3 Axis CNC and at the time i knew very little about them and because of this i made lots of mistakes. The biggest mistake was that the Astrosyn y129-5 12v 0.16A Nema 17 stepper motors where really under powered but i still managed to get the machine to engrave the road runner that came with mach 3 CNC software.

The Stepper controller is the Tachus42 3 Channel Discrete Unipolar from which i built using the instructions on the site and only cost £12 for the parts. The Tachus42 it a good simple controller to start with and because of its simplicity if you let the magic smoke out it can be fairly easy to fix. As with many simple things they lack the more advanced features such as micro stepping and current control, so if you wanted to increase the voltage to the motors above their rated voltage you had to use resistors to dump the extra power which is very wasteful and also very quickly needed very high wattage resistors or build the additional chopper board but this has been known to come with its own set of problems that can be difficult for beginners like my self at the time.

The wood i used was from an old TV cabinet that my next door neighbour was chucking out and i purchased a few drawer slides from ebay i also purchase some 6mm all thread rod from ebay which was another mistake, threaded rod that small just really sucks for a make shift lead screw. i used a cheap dremel type rotary tool as the spindle which worked well when the machine wanted to work.

I learnt a lot from building this machine and although it did not work very well it only fuelled my thirst for a well built CNC so i set about reading everything i could about CNC Machines and started planing my next build Big Red

Big Red v2.0

Big Red 2.0 with perspex sides, MDF Spoilboard and full aluminium construction with the Y Axis linear bearings upgraded to fully supported rails.
The beginning of a quick test of the machine using a pencil to draw Sweet Dreams with a heart ether side which i plan to engrave in some perspex and side light with a few RGB LEDS.

End of test

I`ll add descriptions to the pics soon but basically the little black block is a 1.4w 445nm laser diode that can be pulse at 2w and i have added a vacuum system and the thing with the copper wire wrapped round next to the router is a small camera to help with alignment of the tool. i still need to get the aluminium plate for the front, back, part of the Y- Axis and all the parts for the Z-Axis milled but for now the Big Red has no problem cutting wood and plastic.

i am currently running the motors at 24v 4A but i have still to fit a couple of boost converts to kick the voltage up to the max the drivers can comfortably handle of 40v 4A which will help increase the speed. i have already had the Y Axis running at 3500 mm/sec which is about 137 IPM but for testing i have been running at between 500-1000 mm/sec 19-39 IPM to make sure i dont kill it with one wrong move.


Big Red Version 1

Here is a little about what i plan to accomplish with this machine. I am hoping to end up with a 5 Axis CNC machine that i can change the head to a 3d printer head and have a cutting area of about 1300mm x 1000mm x 240mm.

i will first build a 3 Axis Gantry CNC with hand cut 18mm MDF and then use that machine to cut better quality parts in the hope that a can start to machine aluminium. Then if all goes to plan start making aluminium frame work and build it up to a 5 Axis CNC.

One that is phase is complete i will move onto building the stand along control panel and motion controller using a combo of AVR, Ardunio and TI Stellaris Arm Micro controllers which i hope to use to make a closed loop system using some AS5048A magnetic rotary encoders on each stepper motor shaft. From there i will start work on accessories like auto tool changers, 3D digitizers and all the other fun stuff.

i am still looking for any other parts people could donate like sheets of Plastics ie delrin, hdpe or aluminium that would be great even old machines that i can salvage buttons, electrical and mechanical parts from would be great.

The geek will inherit the earth. 🙂


6 Decade Resistor Substitution Box

I have finally got round to start building the rest of the tools needed for my electronics workshop. I built this Resistor Substitution Box using 6 x 12 Pole Rotary Switches, 6 x Chicken Head Knobs, 1% 1 Watt Metal Film Resistors, 2 x Banana Sockets and some old thick coax cable for connecting the switches together because of its low resistance. Total Cost £7.19 Total Resistance at 0 = 0.3 ohms all the the way up to 999,999 ohms in 1 ohm increments. I am thinking of building another one and a module to connect them together as a potential divider but i might just add a 10k ohm 10 turn potentiometer and and extra socket to the box for that function.