Made some aluminum parts for a 3d printer

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groguard
Posts: 71
Joined: Wed Mar 19, 2014 4:01 am

Made some aluminum parts for a 3d printer

Post by groguard » Sat Apr 26, 2014 8:44 pm

First off I want to say this is the first time Ive milled some aluminum, and I have to say I was impressed with the results. More of the info I needed to cut these I pulled off the forums and the wiki, so most of the credit goes to the shapeoko community for making it happen without blowing something up. Today I made some replacement parts for a friends 3d printer. I milled a modified version of the maxstruder for a mendel v1.5. Its the extruder body and the idler arm. Here is my results

Settings
500mm/min feed
100mm/min plunge
.2mm step down
2 flute center cut end mill(from inventables)
accuracy was +/-.2mm over 3inches
6061 1/8" thick aluminum
and 6061 3/8" thick aluminum
Image
Last edited by groguard on Sat Apr 26, 2014 9:24 pm, edited 1 time in total.
Shapeoko 2 #3920. Nema 23's. Belt drive Z axis, ACME rod upgrade,
1m rails on X and Y, X upgraded to 60x40 extrusion with openrail, Mid span supports,
DW660 with Super-Pid, IC's DW660 dust shoe.
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WillAdams
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Re: Made some aluminum parts for a 3d printer

Post by WillAdams » Sat Apr 26, 2014 9:16 pm

Looks great! Do you know which alloy of aluminum it was?
Shapeoko 3XL #0006 w/Makita RT0701 Router w/0.125″ and ¼″ Elaire precision collets
Nomad 883 Pro #596 (bamboo)

groguard
Posts: 71
Joined: Wed Mar 19, 2014 4:01 am

Re: Made some aluminum parts for a 3d printer

Post by groguard » Sat Apr 26, 2014 9:23 pm

WillAdams wrote:Looks great! Do you know which alloy of aluminum it was?
Thanks! Its all 6061 aluminum :)
Shapeoko 2 #3920. Nema 23's. Belt drive Z axis, ACME rod upgrade,
1m rails on X and Y, X upgraded to 60x40 extrusion with openrail, Mid span supports,
DW660 with Super-Pid, IC's DW660 dust shoe.
Build Log

cvoinescu
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Location: Camberley, UK
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Re: Made some aluminum parts for a 3d printer

Post by cvoinescu » Sun Apr 27, 2014 12:39 am

That looks very, very nicely machined. Congratulations!

To me, that looks like an extruder with a NEMA14 motor (or maybe I have the scale wrong and you have a boss hole larger than 22 mm, or maybe it's a geared NEMA17). The part on the left will have a spring and a bearing attached to it and will press the filament against the drive wheel, and the part on the right will be bent 90 degrees to make the body of the extruder (the lower cut-out is a J-Head-style hot end mount). Am I way off?
Proud owner of ShapeOko #709, eShapeOko #0, and of store.amberspyglass.co.uk

groguard
Posts: 71
Joined: Wed Mar 19, 2014 4:01 am

Re: Made some aluminum parts for a 3d printer

Post by groguard » Sun Apr 27, 2014 12:45 am

cvoinescu wrote:That looks very, very nicely machined. Congratulations!

To me, that looks like an extruder with a NEMA14 motor (or maybe I have the scale wrong and you have a boss hole larger than 22 mm, or maybe it's a geared NEMA17). The part on the left will have a spring and a bearing attached to it and will press the filament against the drive wheel, and the part on the right will be bent 90 degrees to make the body of the extruder (the lower cut-out is a J-Head-style hot end mount). Am I way off?
Thanks for the comments on the quality! Yes you are correct, the larger hole is for a geared nema 17, and the part on the left will have a spring and a bearing and attach as you described. He is going to be bending and tapping the other parts himself.
Here is a picture that I pulled from Makers Tool Works of what it should look like assembled. It is a MendelMax V2 extruder body that has been modified to work with a MendelMax V1.5
http://cdn1.bigcommerce.com/server3200/ ... 00.jpg?c=1
Shapeoko 2 #3920. Nema 23's. Belt drive Z axis, ACME rod upgrade,
1m rails on X and Y, X upgraded to 60x40 extrusion with openrail, Mid span supports,
DW660 with Super-Pid, IC's DW660 dust shoe.
Build Log

Nigel K Tolley
Posts: 226
Joined: Sat Feb 08, 2014 4:06 pm

Re: Made some aluminum parts for a 3d printer

Post by Nigel K Tolley » Sun Apr 27, 2014 10:48 am

That's nice. Is that with the stock spindle?

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groguard
Posts: 71
Joined: Wed Mar 19, 2014 4:01 am

Re: Made some aluminum parts for a 3d printer

Post by groguard » Sun Apr 27, 2014 5:35 pm

Nigel K Tolley wrote:That's nice. Is that with the stock spindle?

Sent from my SM-N9005 using Tapatalk
Im using the Dewalt DW660
Shapeoko 2 #3920. Nema 23's. Belt drive Z axis, ACME rod upgrade,
1m rails on X and Y, X upgraded to 60x40 extrusion with openrail, Mid span supports,
DW660 with Super-Pid, IC's DW660 dust shoe.
Build Log

danimal
Posts: 332
Joined: Wed Mar 13, 2013 5:53 pm
Location: Colorado

Re: Made some aluminum parts for a 3d printer

Post by danimal » Mon Apr 28, 2014 11:59 pm

The 6000 aluminum alloys are the toughest to mill in my experience. They seem to rub and contact weld much easier than the 7000 or 2000 alloys. With that said your parts look fantastic, did you use any cooling or lubrication?
Shapeoko # 1458

RT0701C Spindle || dual y motor || x axis nema23 with custom carriage 1000mm length || z axis nema23 linear rail upgrade with 1/2-10 ACME

groguard
Posts: 71
Joined: Wed Mar 19, 2014 4:01 am

Re: Made some aluminum parts for a 3d printer

Post by groguard » Tue Apr 29, 2014 12:19 am

danimal wrote:The 6000 aluminum alloys are the toughest to mill in my experience. They seem to rub and contact weld much easier than the 7000 or 2000 alloys. With that said your parts look fantastic, did you use any cooling or lubrication?
I used whole lot of WD40 lol :)
Shapeoko 2 #3920. Nema 23's. Belt drive Z axis, ACME rod upgrade,
1m rails on X and Y, X upgraded to 60x40 extrusion with openrail, Mid span supports,
DW660 with Super-Pid, IC's DW660 dust shoe.
Build Log

kmoller
Posts: 9
Joined: Wed Feb 11, 2015 8:11 pm

Re: Made some aluminum parts for a 3d printer

Post by kmoller » Wed Feb 11, 2015 8:20 pm

Hi

do you have the drawing , for the idler arm ? , I am i building , a mendelmax 2 3d printer , and i cant find the drawing for the idler arm!! , and i came across your post while googling

Br.

Kenneth Moller , Denmark

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