sickdeltatube

sickdeltatube

FDM 3D printer with linear delta kinematics and a build area of 350mm in diameter and about 450mm in height.

DISCLAIMER: This is just a personal learning experiment, not a professional project, so I'm not responsible for any disasters that may happen should anyone fiddle with it. Although it can be built and it prints, it is more a "research" tool than a full fledged product.

What I wanted to achieve by creating this:
01) Learn to develop a 3D printer from scratch.
02) Improve my openscad skills (still very poor, don't look at my code if you don't want to be scared, you've been warned).
03) Learn to build a 3D printer from scratch (I've never tried to build any kit or to self source any other open source printer before, they all looked way too difficult for me to understand).
04) Experiment using alu tubes instead of 2020/2040/etc alu profiles for the frame (cheaper, and I don't want to cut/drill/tap).
05) Experiment using laundry cable for hanging to brace the frame (the one with metal wire inside!).
06) Experiment using cable ties instead of screws to keep the frame together (reusable type for faster prototyping! ;).
07) No heat inserts, at all (before you ask: I don't hate heat inserts, I happily use them in building mechanical keyboards, but I wanted to keep this project simple by not forcing myself to put hundreds of them every time I want to try new prototype parts, cable ties are faster and cheaper and just get the job done for this specific use case).
08) Keep the BOM simple and cheap (no difficult to source or too pricey parts), and keep the assembly and the servicing simple and easy.
09) Most "modern" deltas are on the smaller side, or super pricey if big, I wanted to make a delta which was a bit bigger without costing too much to build.
10) Design in a way that could be scaled afterwards, bigger or smaller, within reason, unfortunately due to point 2 I didn't make the code parametric, but the design of the printer is scalable. Maybe to make also the code parametric could be a challenge for my next project ;)
 
What I like of this project:
1) It works! OMG =_)
2) Only 14 stl files. Most of them could be printed inside a 120mm cubed printer. All of them on a 150mm cubed printer IIRC. 
3) It can be unmounted and remounted fast enough for occasional use, very handy if you have few space at home like me ;)
4) It could theoretically print upside down without any mods, but I didn't try yet...
5) It could be easily made AWD by using the motor mount in place of the bearing mount and modifying a bit the bed mounts.

What I don't like of this project:
1) Having to glue the arms to the fisheye joints, I'd really like a build without any glue, will have to research if there is another way to do that.
2) Didn't put a heated bed (yet), I can't find a 24v heater which is big and powerful enough, so I will have to research/learn how to use a mains heater with SSR.
3) The mounts for the PSU and for the spool holder are really ugly, I'd like to improve on those, but at the same time I wanted to release something.
4) The part cooling fan duct is even more ugly than the PSU and spool older :)

TODO: experiment with shorter arms, 42cm is a lot, maybe around 35cm would be better, and experiment with M4 screws for belt tensioning, M3 is not super stable and makes some noises.

some timelapses:
vase mode 016
https://imgur.com/a/sickdeltatube-vase-mode-016-resolution-0pObhmc
dice tower base
https://imgur.com/a/sickdeltatube-dice-tower-OMvJY6q
hulk
https://imgur.com/a/sickdeltatube-hulk-timelapse-SCz2isY
pumpkin vase
https://imgur.com/a/sickdeltatube-timelapse-vase-mode-kyndXyK

Bill Of Materials (to build a printer with 350mm diameter and 450mm height of print area):

FRAME
3 x 1000mm long alu tubes (towers), OD22mm ID18mm: https://www.ebay.it/itm/112283457527                               (20.79 euro)
6 x 500mm long alu tubes (horizontals), OD22mm ID18mm: https://www.ebay.it/itm/112283457527                           (24.66 euro)
10 x M5 cable tensioner: https://www.amazon.it/kippen-1204AK-Confezione-Tenditore-Zincato/dp/B0BW4LNZ1G/              ( 8.00 euro) *
1 x 20m laundry cable: https://www.amazon.it/IPEA-Cavo-Stendibiancheria-Acciaio-Plastificato/dp/B0994LTXTF/           ( 7.99 euro) *
10 x M4 cable holder: https://www.amazon.it/QWORK-Ampiamente-NellIndustria-NellEdilizia-NellAncoraggio/dp/B09XTR8BMH/ ( 9.76 euro)
20 x M8 22mm C44418 shims: https://www.amazon.it/AERZETIX-Rondelle-montaggio-serraggio-fissaggio/dp/B08GG1PH1P/       ( 7.59 euro) *
30 x M5x30mm PINs: https://www.amazon.it/gp/product/B0CBRJNXL2/                                                       (28.17 euro)
FRAME TOTAL: 114.55 euro

MOTION
6 x 1000mm rods: https://www.ebay.it/itm/164233354815                                                                         (79.08 euro)
6 x 6 LM12UU bearings: https://www.ebay.it/itm/152615209694                                                                   (15.18 euro)
50 x M3x12mm shims: https://www.amazon.it/Rondelle-metallo-inox-Anti-corrosione-esterno-interno/dp/B0B37LQ3LX/                (13.19 euro) *
20 x M3x30mm hexagonal head screws: https://www.amazon.it/Bullone-esagonali-esagonale-antiruggine-portaoggetti/dp/B0BRHG24QK/ (15.46 euro) *
50 x M3x40mm screws: https://www.amazon.it/gp/product/B0DDJ9QV4T/                                                             ( 9.49 euro)
10 x F695 bearings https://www.aliexpress.com/item/33001186278.html                                                           ( 9.59 euro) *
3 x NEMA17 motors with cable: https://www.amazon.it/STEPPERONLINE-passo-passo-42x42x39mm-connettore-fresatrice/dp/B0B38GX54H/ (35.55 euro)
40 x M3 nuts: https://www.amazon.it/gp/product/B0BDDPQJ9L/                                                                    ( 6.99 euro) *
1 x 8m POWGE GT2 6mm wide belt: https://it.aliexpress.com/item/902692789.html                                                 (14.89 euro) *
10 x POWGE 20T 5mm bore toothed idler: https://s.click.aliexpress.com/e/_DB4U4JB                                              (13.59 euro) *
20 x D3xM2.5x25mm shoulder bolts: https://it.aliexpress.com/item/1005007325571669.html                                        ( 9.72 euro) *
50 x M2.5 hex nuts: https://it.aliexpress.com/item/1005007593861199.html                                                      ( 3.76 euro) *
12 x Ball link V1 7mm diameter M3/3 "MPJ 2455 B" https://mpjet.com/shop/gb/ball-7-mm-dia/1284-372-ball-link-v1-type-7-mm-dia-m33.html#/11-colour-b_black (20.66 euro)
6 x alu tubes OD8mm ID6mm 400mm lenght: https://www.ebay.it/itm/112283454937?var=412699471265                                 (19.54 euro)
MOTION TOTAL: 266.69 euro

EXTRUDER+HOTEND
1 x Extruder HGX LITE with pancake motor: https://it.aliexpress.com/item/1005005459467999.html (39.49 euro)
1 x Hotend Clone Bambu Lab X1C (the one with separated wiring): https://www.aliexpress.com/item/1005006035385996.html (17.69 euro)
EXTRUDER+HOTEND TOTAL: 57.18 euro

BED 
1 x 370mm diameter 3mm thickness glass bed: https://www.ebay.it/itm/165277709394                          (28.19 euro)
1 x 370mm diameter 2mm thickness FR4 build surface: https://www.ebay.it/itm/264758530992?var=564583570176 (27.88 euro)
10 x M8x60mm screws https://www.amazon.it/Bulloni-Brugola-Acciaio-cilindrica-incassato/dp/B08RMST1CQ      (15.49 euro)
BED TOTAL: 71.56 euro

ELECTRONICS
1 x SKR Pico v1.0: https://it.aliexpress.com/item/1005006043530249.html    (19.76 euro)
1 x sunon 2510 5v: https://www.amazon.it/dp/B07FZZQJ2W                     (10.85 euro)
2 x furiga 5015 24v: https://www.amazon.it/dp/B08PV27LVM                   (11.99 euro) *
6 x optical endstops: https://it.aliexpress.com/item/1005005304758202.html ( 2.83 euro) *
1 x meanwell lrs-350-24: bought second hand on ebay with rocker/C13        (30.00 euro)
ELECTRONICS TOTAL: 75.43 euro

FILAMENT (should be under 2Kg, but if you want to make all corners and all motor and bearing/idler mounts same color it is 1313.13g those alone)
1 x Overture ABS purple: https://www.amazon.it/dp/B0BNVJ9GDJ (18.69 euro)
1 x Amazon ABS blue: https://www.amazon.it/dp/B07SZLYHTW     (16.14 euro)
FILAMENT TOTAL: 34.83 euro

* probably less is/are needed but I could not find the exact quantity sold on amazon/ebay/aliexpress (for example: I need 4 screws but they are sold in packs of 10)
P.S.: you will need 4 short M4 screws to hold the PSU and 6 short M3 screws to hold the endstops, any will do, I've got these:
https://www.amazon.it/Bulloni-Pezzi-Esagonale-Rondelle-Brugola/dp/B0D1V2JL28
https://www.amazon.it/Bulloni-Rondella-Cilindrica-Incassato-Esagonale/dp/B0DDKC6B8X
P.P.S.: I've used these connectors and cables for cabling but you can use any that you already have or see fit for purpose:
JST XH 2.54 male/female with AWG24 wire: https://www.amazon.it/gp/product/B07QMMC4WZ/
XT60 connectors male/female for the bed heater which I don't yet have: https://www.amazon.it/Femmina-Maschio-Connettore-Silicone-Batteria/
AWG14 red/black cable: https://www.amazon.it/Makerfire-elettrico-flessibili-temperature-aeroplani/
P.P.P.S: gorilla glue to glue the arms to the fisheye joints:
https://www.amazon.it/GORILLA-COLLA-SIRINGA-RESINA-EPOSSIDICA/dp/B0BHJKZSCP
P.P.P.P.S: optional, a detatchable probe if you don't want to do manual delta calibration:
https://www.amazon.it/dp/B07V6GR72Q


BOM GRAND TOTAL: 620.24 euro


Some considerations on the BOM:
1) Amazon/ebay/aliexpress can vary in price and shipping, I don't even exactly remember if I've calculated shipping, but VAT should be in.
   You could probably build for less if you try to buy as much parts as you can find on aliexpress or if you wait for when they are on offer.
2) I've tried to put everything to build from scratch, but it could be that many things you already have in your lab or from some other printer/project to reuse.
3) Because of point 2 I've just used an old i5 notebook I had around (thinkpad x260), installed armbian and klipper, no small sbc needed.
4) For the same price of this BOM a better premade commercial 3D printer could be bought, maybe enclosed, but the aim of this project is not to compete with the resources of a 3D printer producer, a mass produced printer will always be cheaper, this project provides a fully open source and customizable linear delta printer, with a big print area, both of these things I could not find on the market.

SO, if all this didn't discourage you, the first one to build this printer and post the make here will receive the coveted #001 serial number :PPP
You will find the printguide pictures and the buildguide pictures respectively in the sickdeltatubeprintguide.zip and sickdeltatubebuildguide.zip files or in subfolders with the same name.
I also added a guide to install and configure klipper in armbian, but it's just for reference, you don't have to follow that.

THANKS TO FOR INSPIRATION:
https://www.printables.com/model/857334-min-micro-delta-3d-printer
https://github.com/rolohaun/PhoenixDelta
https://www.printables.com/model/157231-kossel-wire-cable-frame-braces-2020-unlock-warp-sp

THANKS FOR ANSWERING ALL MY QUESTIONS:
The guys in the #delta-printers channel on the Rolohaun3D discord: https://discord.com/invite/rolohaun-3d-946191040682008666
The guys in the #3d-printing channel on the matt3o discord: http://discord.gg/xBVuZnjDM2
The guys in the Viking3D discord: https://discord.gg/mWARcpt7NQ

P.S.: NEW ARMS AND HEATED BED

ARMS: https://it.aliexpress.com/item/1005009471848677.html OD8 ID6 color purple 350mm custom cut 67euro shipped from china

BED SSR: https://www.amazon.it/dp/B0CW8NJVB5?ref=ppx_yo2ov_dt_b_fed_asin_title 40A DC 3-32V DC out 480V AC 16euro shipped from amazon it

BED HEATER: https://it.aliexpress.com/item/1005008017601404.html 350mm diameter 800w 220v 45,98euro shipped from china

(I've also put a jig to help center the heater in the bed: bedheaterpadjig.scad and bedheaterpadjig.stl I've used it to mark a circle line and glue the heater inside)

P.P.S.: NEW CARRIAGE A BIT EASIER TO MOUNT AND TENSION sickdeltatube_carriageback_x3_v1.4.stl and sickdeltatube_carriagefront_x3_v1.7.stl