So some of you might know that I do almost all my printing on my 3-year-old MakerBot Replicator 2X. It’s been a real workhorse and continues to serve me well (knock on wood). However, one of its shortcomings (reads: constraints) for the Ultrascope Explorer build is the machine’s build volume. I know, I know... the 2X is still bigger than many others out there. Because of the limitations I’ve had some of the parts printed for me by my local 3D Printing supply shop. I try to avoid this when I can because of the time it can sometimes take.
When I started building my first Ultrascope a few years ago, the design was a bit smaller because the original plan called for a 4 inch (100 mm) primary mirror. Even though some of the pieces wouldn’t fit (under normal circumstances), creative arrangement aloud me to still get them made.
I realize that most hobbyists aren’t using supersized printers with volume to spare. Thankfully the cost to size ratio is changing in our favor as the industry matures. That said, it doesn’t help us today.
Let’s look at Hexagon 5 as an example of a part that too big to fit in the build volume of most printers.
I took a look at the part in Onshape and figured that I could likely cut it into three pieces while still maintaining the strength needed. I made the new pieces 15 mm taller to accommodate the new overlapping joints.
I’m running a test batch starting tonight (18/Apr/17) to see if the bits will work together the way I’d hope.
I’d love to hear your feedback and/or suggestions to make to project and design better.
Update: 19/Apr/17
The first print of what I’m calling Hex 5-A came out great.
Now I just need to print Hex 5-B and 5-C and do a test fit.
Update: 20/Apr/17
After attaching some OpenBeam, it’s clear (to me, not so clear in the picture) that some minor changes need to be made.
Update: 12/May/17
I had to print Hex 5-B a few time before I got a complete part. I had five failed/ ghost prints before switching filament (which gave me a perfect part on the first try). I realized I was using the last of an ABS spool that was more than two-years old. The rest of it is now in the trash so I don’t make that mistake again. New Best Practice: Take a silver Sharpie and date your filament spools.
I cleaned it up and added it to Hex 5-A. It fit great, but the nuts and cap screws gave me a bit of trouble when I tried to line them up in the makerbeam. My guess is user error since I didn’t have any problems once things were tight.
Update: 15/May/17
I finished printing the test pieces yesterday and I’m happy to report that they fit quite well. I never printed hex 5-C, just 5-A, and 5-B twice. If you want to print these for yourself, you can get the .STL files on my MODs section of Wevolver.
More to come
Project by The Open Space Agency
Designed using OnShape
Hosted on Wevolver
Modification Files are housed on Wevolver
Other project pictures on INSTAGRAM
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