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DD1 - Ultimaker Direct Drive (lasercut) - Beta

by chopmeister, published

DD1 - Ultimaker Direct Drive (lasercut) - Beta by chopmeister Mar 7, 2013

Description

UPDATE 13.2.2014. I am thinking of changing this design to be completely printable, and working on that currently. Stay tuned.

This is an upgrade for the UM, which enables you to get rid of the short belts on your X and Y axis. The original concept was made and developed by snowygrouch, as presented on the Ultimaker forum, the difference being that his design uses printed mounts for the motors, while I am trying to make the thing with lasercut parts. You can find instructions and files for his version here: calumdouglas.ch so go take a look.

The reason behind this upgrade is to have one less source of potential backlash, and thus more precision.

Recent Comments

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Hi, I was just thinking, is it possible to 3d print out the parts with 4mm thickness ABS and then we assemble them into the direct drive set?

There's tons of them on ebay and they're really cheap. Just search for "5mm 8mm coupling".

Hi, does anybody know where to buy 5/8 couplings ? A link to a german webshop would be nice as i can't find these things anywhere via google...

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Instructions

UPDATE[13.04.2013]:
I think I am on the verge of solving how to have repeatable results when assembling this thing, so that it won't really matter if different laser cutters produce slightly different parts, while still maintaining a tight fit. So I think this will be out of beta soon, together with the final plans and instructions. Also I've uploaded a photo how it currently looks on my machine.

This is still in beta. The plans are here, and I have successfully installed it on my UM. It works and prints fine. I've done about 15+ hours of printing on it and it runs just fine with no noticeable problems. The sound of my motors has changed a bit though.

I recommend making this out of wood instead of acrylic for two reasons: acrylic is more prone to breaking, especially on the thinner sections, you have to be really careful, and more importantly the system relies on every slot-in connection being really tight, which is very hard to do with acrylic if you don't have your own laser cutter. With wood however you can always sand out a bit, and push a bit harder. Also, acrylic tends to produce more sound.

The plans are NOT made to compensate for the laser beam thickness, because it differs too much from one machine to the other so both the connections and slots are drawn with the same dimensions (mostly 4mm). It would be best to test cut 2 parts then adjust the drawings if necessary.

You will need a 225x170mm sheet of 4mm wood or 4 mm acrylic, a bag of M3 nuts and various M3 bolts. (full list to be added later). You will also need one 8mm linear rod to cut to size for the Y axis. You can reuse the old Y-axis rod for the new X-axis. 2x 5/8mm flexible couplers and a drill with a 3mm sized bit. Yes I want you to drill holes on your precious Ultimaker. :)

The installation is very nasty business because of some hardly reachable places where bolts are needed. Detailed instructions will come, unfortunately I don't have time at the moment to finish them.

All in all, I recommend this for people who have a laser cutter. It's too expensive to mess around with otherwise, and I recommend snowygrouch's original printed version in that case.

Comments

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dabiuque on Oct 28, 2013 said:

Hi, I was just thinking, is it possible to 3d print out the parts with 4mm thickness ABS and then we assemble them into the direct drive set?

anwofi on May 20, 2013 said:

Hi, does anybody know where to buy 5/8 couplings ? A link to a german webshop would be nice as i can't find these things anywhere via google...

chopmeister on May 20, 2013 said:

There's tons of them on ebay and they're really cheap. Just search for "5mm 8mm coupling".

chopmeister on Apr 13, 2013 said:

Oh and if anybody is wondering, the blurry greenish-yellow thing in the background is the current H4 extruder prototype :)

fns720 on Apr 20, 2013 said:

Wow! When do you plan to release it? :)

fns720 on Apr 10, 2013 said:

Hi,

Is this out of beta stage yet?

chopmeister on Apr 10, 2013 said:

Hi,
It's 100% working, that I can say. Although, I an thinking of redesigning it all with 5mm thick wood/acrylic instead of 4, for extra stiffness. When that is done, it will be out of beta. Unfortunately I can't say when that'll happen, because I'm working on 2 different new extruders, which have priority, not to mention my day job :)

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