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Jolt & friends - Team Overkill - NSW
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Nick
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Joined: 16 Jun 2004
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Location: Sydney, NSW


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Update: The high-temp extruder is installed on the Wanhou and the first PC-Max print is half done. After following the Polymaker instructions to the letter, the print stuck to the bed perfectly and what I can see of the surface finish looks as good or better than what I expect with PLA.

I am really not a fan of rafts, so th next print will go straight on the bed - as long as it has plenty of contact area, I think it will stick just fine.
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Post Sun Mar 19, 2017 2:12 pm 
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evil_steve



Joined: 06 Sep 2015
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Location: Adelaide, SA


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Awesome, can't wait to see the result! My printer is actually having the print bed repaired under warranty at the moment as it stopped heating up at all - once I get it back I'll try the polycarbonate again. PC Plus is supposed to print on the Robox without buildtak using a hotter bed.

Post Sun Mar 19, 2017 3:35 pm 
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Nick
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Now that the part is finished, I can see it warped slightly at the base - probably due to the 100% in-fill. The raft stuck to the Buildtak quite well but not as much as PLA, which almost needs to be hammered off! The next time I will try using a smaller separation distance between the raft and the part to see if the warping can be tamed. I used the middle of the range printing temp, so upping that a bit might help bed adhesion.

The Polymaker instructions mention that parts can be annealed for an hour at 100 C to 'remove stress and strengthen the part' so maybe that is a possible bed temperature - if the filament sticks, perhaps it will stay too hot to warp.
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Post Sun Mar 19, 2017 4:25 pm 
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Nick
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Warping fixed:

I turned the bed up to 100C and reduced the recommended gap between the raft & part down from 0.4mm to 0.2mm - the raft sticks to the Buildtak almost better than the Buildtak sticks to the platform and the part now has almost zero warp. Its still there but you need a ruler to detect it Smile. Next time I will try 90 C for the bed to preserve the Buildtak - that stuff doesn't grow on trees, y'know.
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Post Sun Mar 19, 2017 9:06 pm 
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Nick
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Printed wheels:

The first test of Ninjaflex wheels is looking plausible - not perfect but worth more testing. With a 15mm thick by 32mm wide test block, there is a reasonable amount of deflection under Mr Mangle's wheel:



The pad has five surface layers and a 25% infill and there is some extra weight on the bot to simulate the metal frame and missing parts. For the next test I will do a lower in-fill and a thicker pad so see if I can get a little more deflection. The main problem with this idea is that Ninjaflex has a shore hardness of 90A and is not particularly grippy. The solution could be to paint the wheel in a softer urethane to give it more grip. The other problem is the low printing speed; just the small test pad took four hours and a full wheel is predicted to take over 20 hours.

CNC enclosure:

I got back to work on the enclosure and the final four sections are welded in:



Now the hard part, standing the frame up. If its holds off raining tomorrow, I will get a bunch of timber and start cutting out the roof beams before hooking up the chain hoist and attempting to get the frame upright.
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Post Mon Mar 20, 2017 6:18 pm 
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miles&Jules
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That frame is Looking mega -not going to take up to much room in ya new shed is it?
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Post Tue Mar 21, 2017 1:13 am 
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Nick
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At the moment it effectively takes up a third of the workshop and its a real PITA to get around it! Once it is standing up and pushed against a wall, it will be much more reasonable. It was surprisingly easy to weld it all together but now I'm wondering if would have been easier to weld the frame in the vertical position - standing the frame up is going to be a nightmare!
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Post Tue Mar 21, 2017 7:31 am 
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Nick
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Robot Wars:

Mr Mangle (or any other Featherweights) won't be going to RW this year - after all the work put in to the upgrade, the feather division was cancelled. I am really gutted but things have to move on; there may be a Robochallenge Championship in late August as part on the Insomnia 61 gaming event. Robot gods; if you are listening, please make that happen!

Wheels:

I decided to skip small scale testing and print a complete wheel:



It was printed at a slightly higher speed (15mm / sec) than the other test parts and that was a huge mistake:



The wheel has major stringing and bonding problems, making it noticeably weaker. The next version is printing at 8mm / sec and looks perfect - but its taking 26 hours
Shocked. The dodgy print will still be fine for fitting a hub and glue adhesion tests.
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Post Thu Mar 23, 2017 2:24 pm 
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Cpnwolfe



Joined: 29 May 2012
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26hrs holy but hey still cheaper the RMP! Very Happy
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Post Thu Mar 23, 2017 5:42 pm 
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Nick
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They are very light as well as they are mostly air. The first attempt only weighs 48 grams.
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Post Thu Mar 23, 2017 6:01 pm 
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Nick
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CNC Enclosure

What trickery is this - is it witchcraft or a multi-axis attachment for the enclosure? Smile



The temporary wheels allowed the enclosure to be centred under a roof beam and helped save the floor from scratches while it was being lifted.

The chain hoist made lifting the enclosure easy, except I had to stand inside the metalwork to use it.



And the enclosure is finally standing up Smile:



There is still a heap of work to do: finish the welds that couldn't be reached before, sand and paint the frame, add the plywood skin, the list seems endless.
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Post Fri Mar 24, 2017 12:17 pm 
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Valen
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Looking good man
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Post Fri Mar 24, 2017 1:13 pm 
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Nick
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Not looking so good:



The print came out perfect, the Buildtak sheet, not so much - it was only a week old too Crying or Very sad
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Post Fri Mar 24, 2017 3:14 pm 
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Ellis



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That's a bit crap! Might be able to get some compensation from the company?
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Post Sat Mar 25, 2017 12:06 pm 
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Nick
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Not likely - the Buildtak was a freebie with a roll of Polymaker filament. I have a spare sheet but they are a HUGE pain in the ass to peel off - which just shows how well Ninjaflex sticks to the bed! I can try changing the settings for the first layer to make it stick less - maybe more speed or less extrusion. There is enough space left on the bed to get it right before I replace it with a new sheet.
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Post Sat Mar 25, 2017 1:38 pm 
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