https://reprap.org/mediawiki/api.php?action=feedcontributions&user=Free&feedformat=atomRepRap - User contributions [en]2024-03-29T11:14:00ZUser contributionsMediaWiki 1.30.0https://reprap.org/mediawiki/index.php?title=00str00der2&diff=13687300str00der22014-11-29T07:29:31Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_first_extruder_pulley.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original [[00str00der#Version_1.3]], it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
[[File:00str00der2 assembly top.png |400px|large|left|OpenSCAD model of assembled 00str00der2]]<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the [[00str00der]] belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original design has been revised several times and proven in the field by Terawatt Industries and Reprap users. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had possibly filed a controversial patent in 2014 over that design, but no matter. I never intended a quick-release because the Greg's-style designs have never worked for me: the pivoting screws wear out and break the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the mount gender -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
[[File:00str00der2_first_extruder_pulley_idler.png|400px|large|right|first-ever 00str00der2 with attached pulley and idler]]<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* M4 mounting hardware<br />
* 1x NEMA 17 Stepper Motor<br />
* 1x GT2 60T pulley, 6mm width<br />
* 1x GT2 16T pulley, 6mm width<br />
* 1x GT2 90T belt, 2mm spacing, 6mm width<br />
TBD<br />
<br />
Although 00str00der2 is a WIP, the 2.0 BOM is available from KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v20 http://kitbom.com/terawattindustries/00str00der-extruder-v20].<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assembly (with all including nuts, bushings, roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
18.11.2014 - The attached photo shows some of the first prototypes for idler rollers. Metal on metal works OK but not very well under pressure or on threads. After further thought the idler bolt will have to be M4. The teflon bushing will need an inner liner and I am going to try printing a tiny part for this, otherwise it will have to be metal. I may modify the design to use rubber washers and teflon washers.<br />
<br />
=== M6 Knurled Bolt ===<br />
[[File:m6_knurled_bolt.png|400px|small|right|M6 knurled bolt by Terawatt Industries for 00str00der2]]<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* M6 idler roller with 1x teflon bushing and 2x teflon washers<br />
* 6x M6 jam nuts<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der2 sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der2:<br />
# Use the 00str00der2 Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der2+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. NOTE: update required to PrismX for 00str00der2 mounting holes. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
First prototype printed with 3.5mm shell and 35% infill. The acetal bushings fit well but maybe a little more clearance - maybe, if so less than 1mm. It looks like the assembly needs teflon washers next to the acetal bushings, on the knurled bolt. The metal on acetal works acceptably but it needs to be smoother. No design changes are needed for this so I am going to machine some and update. The idler fits really well but requires M4x45mm and I think a recessed cavity will allow M4x40mm and then clear the pulley nicely.<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13687100str00der22014-11-29T07:19:43Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_first_extruder_pulley.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original [[00str00der#Version_1.3]], it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the [[00str00der]] belt-driven extruder.<br />
[[File:00str00der2_first_extruder_pulley_idler.png|400px|large|right|first-ever 00str00der2 with attached pulley and idler]]<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original design has been revised several times and proven in the field by Terawatt Industries and Reprap users. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* M4 mounting hardware<br />
* 1x NEMA 17 Stepper Motor<br />
* 1x GT2 60T pulley, 6mm width<br />
* 1x GT2 16T pulley, 6mm width<br />
* 1x GT2 90T belt, 2mm spacing, 6mm width<br />
TBD<br />
<br />
Although 00str00der2 is a WIP, the 2.0 BOM is available from KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v20 http://kitbom.com/terawattindustries/00str00der-extruder-v20].<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assembly (with all including nuts, bushings, roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
18.11.2014 - The attached photo shows some of the first prototypes for idler rollers. Metal on metal works OK but not very well under pressure or on threads. After further thought the idler bolt will have to be M4. The teflon bushing will need an inner liner and I am going to try printing a tiny part for this, otherwise it will have to be metal. I may modify the design to use rubber washers and teflon washers.<br />
<br />
=== M6 Knurled Bolt ===<br />
[[File:m6_knurled_bolt.png|400px|small|right|M6 knurled bolt by Terawatt Industries for 00str00der2]]<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* M6 idler roller with 1x teflon bushing and 2x teflon washers<br />
* 6x M6 jam nuts<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der2 sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der2:<br />
# Use the 00str00der2 Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der2+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. NOTE: update required to PrismX for 00str00der2 mounting holes. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
First prototype printed with 3.5mm shell and 35% infill. The acetal bushings fit well but maybe a little more clearance - maybe, if so less than 1mm. It looks like the assembly needs teflon washers next to the acetal bushings, on the knurled bolt. The metal on acetal works acceptably but it needs to be smoother. No design changes are needed for this so I am going to machine some and update. The idler fits really well but requires M4x45mm and I think a recessed cavity will allow M4x40mm and then clear the pulley nicely.<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=File:M6_knurled_bolt.png&diff=136869File:M6 knurled bolt.png2014-11-29T07:15:04Z<p>Free: M6 knurled bolt by Terawatt Industries</p>
<hr />
<div>M6 knurled bolt by Terawatt Industries</div>Freehttps://reprap.org/mediawiki/index.php?title=File:00str00der2_first_extruder_pulley.png&diff=136868File:00str00der2 first extruder pulley.png2014-11-29T06:52:18Z<p>Free: </p>
<hr />
<div>First-ever 00str00der2 prototype. This is the tower with 60T GT2 pulley and M6 knurled bolt.</div>Freehttps://reprap.org/mediawiki/index.php?title=File:00str00der2_first_extruder_pulley.png&diff=136867File:00str00der2 first extruder pulley.png2014-11-29T06:52:06Z<p>Free: </p>
<hr />
<div>First 00str00der2 prototype. This is the tower with 60T GT2 pulley and M6 knurled bolt.</div>Freehttps://reprap.org/mediawiki/index.php?title=File:00str00der2_first_extruder_pulley_idler.png&diff=136866File:00str00der2 first extruder pulley idler.png2014-11-29T06:51:31Z<p>Free: First ever 00str00der2 prototype. This is the extruder tower with 60T GT2 pulley, M6 hobbed bolt, and attached idler opened to full extension. Also shown are a couple of conceptual prototypes for the idler roller.</p>
<hr />
<div>First ever 00str00der2 prototype. This is the extruder tower with 60T GT2 pulley, M6 hobbed bolt, and attached idler opened to full extension. Also shown are a couple of conceptual prototypes for the idler roller.</div>Freehttps://reprap.org/mediawiki/index.php?title=File:00str00der2_first_extruder_pulley.png&diff=136865File:00str00der2 first extruder pulley.png2014-11-29T06:48:54Z<p>Free: First 00str00der2 prototype. This is the tower with 60T GT2 pulley.</p>
<hr />
<div>First 00str00der2 prototype. This is the tower with 60T GT2 pulley.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13651200str00der22014-11-28T06:26:27Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original [[00str00der#Version_1.3]], it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the [[00str00der]] belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original design has been revised several times and proven in the field by Terawatt Industries and Reprap users. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* M4 mounting hardware<br />
* 1x NEMA 17 Stepper Motor<br />
* 1x GT2 60T pulley, 6mm width<br />
* 1x GT2 16T pulley, 6mm width<br />
* 1x GT2 90T belt, 2mm spacing, 6mm width<br />
TBD<br />
<br />
Although 00str00der2 is a WIP, the 2.0 BOM is available from KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v20 http://kitbom.com/terawattindustries/00str00der-extruder-v20].<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assembly (with all including nuts, bushings, roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* M6 idler roller with 1x teflon bushing and 2x teflon washers<br />
* 6x M6 jam nuts<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der2 sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der2:<br />
# Use the 00str00der2 Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der2+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. NOTE: update required to PrismX for 00str00der2 mounting holes. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13651100str00der22014-11-28T06:25:46Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original [[00str00der (version 1.3) 00str00der#Version_1.3]], it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the [00str00der 00str00der belt-driven extruder].<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original design has been revised several times and proven in the field by Terawatt Industries and Reprap users. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* M4 mounting hardware<br />
* 1x NEMA 17 Stepper Motor<br />
* 1x GT2 60T pulley, 6mm width<br />
* 1x GT2 16T pulley, 6mm width<br />
* 1x GT2 90T belt, 2mm spacing, 6mm width<br />
TBD<br />
<br />
Although 00str00der2 is a WIP, the 2.0 BOM is available from KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v20 http://kitbom.com/terawattindustries/00str00der-extruder-v20].<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assembly (with all including nuts, bushings, roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* M6 idler roller with 1x teflon bushing and 2x teflon washers<br />
* 6x M6 jam nuts<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der2 sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der2:<br />
# Use the 00str00der2 Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der2+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. NOTE: update required to PrismX for 00str00der2 mounting holes. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13651000str00der22014-11-28T06:22:58Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original [00str00der#Version_1.3 00str00der (version 1.3)], it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the [00str00der 00str00der belt-driven extruder].<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original design has been revised several times and proven in the field by Terawatt Industries and Reprap users. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* M4 mounting hardware<br />
* 1x NEMA 17 Stepper Motor<br />
* 1x GT2 60T pulley, 6mm width<br />
* 1x GT2 16T pulley, 6mm width<br />
* 1x GT2 90T belt, 2mm spacing, 6mm width<br />
TBD<br />
<br />
Although 00str00der2 is a WIP, the 2.0 BOM is available from KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v20 http://kitbom.com/terawattindustries/00str00der-extruder-v20].<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assembly (with all including nuts, bushings, roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* M6 idler roller with 1x teflon bushing and 2x teflon washers<br />
* 6x M6 jam nuts<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der2 sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der2:<br />
# Use the 00str00der2 Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der2+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. NOTE: update required to PrismX for 00str00der2 mounting holes. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13650900str00der22014-11-28T06:17:04Z<p>Free: /* Materials */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* M4 mounting hardware<br />
* 1x NEMA 17 Stepper Motor<br />
* 1x GT2 60T pulley, 6mm width<br />
* 1x GT2 16T pulley, 6mm width<br />
* 1x GT2 90T belt, 2mm spacing, 6mm width<br />
TBD<br />
<br />
Although 00str00der2 is a WIP, the 2.0 BOM is available from KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v20 http://kitbom.com/terawattindustries/00str00der-extruder-v20].<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assembly (with all including nuts, bushings, roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* M6 idler roller with 1x teflon bushing and 2x teflon washers<br />
* 6x M6 jam nuts<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der2 sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der2:<br />
# Use the 00str00der2 Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der2+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. NOTE: update required to PrismX for 00str00der2 mounting holes. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=13650500str00der2014-11-28T02:19:33Z<p>Free: /* Version 1.3 */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for the UConduit H-Bot 3D Printer with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs have converged (rev. C = 1.0) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]].<br />
<br />
The 00str00der is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, supports different size pulleys and belts for varying gear ratios, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users.<br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
Version 1.2 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v12<br />
<br />
Version 1.3 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v13<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
* hardware BOM has changed in version 1.2; refer to "Version History" section.<br />
* hardware BOM has changed in version 1.3; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Assembly instructions===<br />
A few people have put an 00str00der kit together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
The 00str00der has an (OpenSCAD) parametrized variant for a Bowden setup. In this variant the bore for the j-head is replaced with one that accommodates a press-to-fit connector. It also has mounting holes on the side for a right-angle attachment to a printer frame. Pictures of UConduit H-bot repraps show this setup in action.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody still needs to design a mount for other types of frame materials...<br />
<br />
=== Version History ===<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
==== Version 0.9 ====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
==== Version 1.0 ====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
==== Version 1.1 ====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
==== Version 1.2 ====<br />
Considered stable. Same as version 1.1 but with slightly modified idler for M4. No more M3 hardware, just M4 and M8 in BOM.<br />
<br />
The complete version 1.2 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v12 http://kitbom.com/terawattindustries/00str00der-extruder-v12].<br />
<br />
==== Version 1.3 ====<br />
Considered stable. Same as version 1.2 but with 65mm M8 knurled/hobbed bolt and 1x M8 jam nut. The 65mm M8 bolt is still knurled/hobbed at 30mm from the head. A knurled socket cap M8x65mm screw is preferred, as usually supplied by Terawatt. 60mm might not cut it, but you can still use the rest of the BOM just skip the M8 jam nut.<br />
<br />
The M8 jam nut is for use between big pulley and 608 bearing to reduce hobbed bolt wobble. It should be hand-tightened against the 608 bearing on the big pulley side during assembly. Then the big pulley is pressed snugly against the jam nut and locked into place with its set screw.<br />
<br />
The complete version 1.3 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v13 http://kitbom.com/terawattindustries/00str00der-extruder-v13].<br />
<br />
=== Optional Parts ===<br />
==== JK Adapter Plate ====<br />
The adapter/mounting plate provides support for attaching the 00str00der to a Kuehling's compatible x-carriage, as described in "Upgrade/Retrofit". There are three (3) mounting holes for attaching the 00str00der to the plate. When using this setup, the extruder is rotated 90 degrees, perpendicular to the axis of motion. The plate can be machined or cast.<br />
<br />
==== 00dapter ====<br />
The 00dapter was added in 2014. The 00dapter provides compatibility for using an 00str00der with a Budaschnozzle. The 00dapter is based on the "Budapter" found on Thingiverse. It's intended to be used with the JK Adapter Plate. It is installed into the 00str00der grove-mount and fills the gap between the JK Adapter Plate and the Budschnozzle mount-plate.<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=13650400str00der2014-11-28T02:19:03Z<p>Free: /* Version 1.3 */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for the UConduit H-Bot 3D Printer with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs have converged (rev. C = 1.0) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]].<br />
<br />
The 00str00der is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, supports different size pulleys and belts for varying gear ratios, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users.<br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
Version 1.2 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v12<br />
<br />
Version 1.3 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v13<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
* hardware BOM has changed in version 1.2; refer to "Version History" section.<br />
* hardware BOM has changed in version 1.3; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Assembly instructions===<br />
A few people have put an 00str00der kit together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
The 00str00der has an (OpenSCAD) parametrized variant for a Bowden setup. In this variant the bore for the j-head is replaced with one that accommodates a press-to-fit connector. It also has mounting holes on the side for a right-angle attachment to a printer frame. Pictures of UConduit H-bot repraps show this setup in action.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody still needs to design a mount for other types of frame materials...<br />
<br />
=== Version History ===<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
==== Version 0.9 ====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
==== Version 1.0 ====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
==== Version 1.1 ====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
==== Version 1.2 ====<br />
Considered stable. Same as version 1.1 but with slightly modified idler for M4. No more M3 hardware, just M4 and M8 in BOM.<br />
<br />
The complete version 1.2 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v12 http://kitbom.com/terawattindustries/00str00der-extruder-v12].<br />
<br />
==== Version 1.3 ====<br />
Considered stable. Same as version 1.2 but with 65mm M8 knurled/hobbed bolt and 1x M8 jam nut. The 65mm M8 bolt is still knurled/hobbed at 30mm from the head. A knurled socket cap M8x65mm screw is preferred, as usually supplied by Terawatt. 60mm might not cut it, but you can still use the rest of the BOM just skip the M8 jam nut. The M8 jam nut is for use between big pulley and 608 bearing to reduce hobbed bolt wobble. It should be hand-tightened against the 608 bearing on the big pulley side during assembly. Then the big pulley is pressed snugly against the jam nut and locked into place with its set screw.<br />
<br />
The complete version 1.3 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v13 http://kitbom.com/terawattindustries/00str00der-extruder-v13].<br />
<br />
=== Optional Parts ===<br />
==== JK Adapter Plate ====<br />
The adapter/mounting plate provides support for attaching the 00str00der to a Kuehling's compatible x-carriage, as described in "Upgrade/Retrofit". There are three (3) mounting holes for attaching the 00str00der to the plate. When using this setup, the extruder is rotated 90 degrees, perpendicular to the axis of motion. The plate can be machined or cast.<br />
<br />
==== 00dapter ====<br />
The 00dapter was added in 2014. The 00dapter provides compatibility for using an 00str00der with a Budaschnozzle. The 00dapter is based on the "Budapter" found on Thingiverse. It's intended to be used with the JK Adapter Plate. It is installed into the 00str00der grove-mount and fills the gap between the JK Adapter Plate and the Budschnozzle mount-plate.<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=13650300str00der2014-11-28T02:14:54Z<p>Free: /* Version 1.3 */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for the UConduit H-Bot 3D Printer with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs have converged (rev. C = 1.0) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]].<br />
<br />
The 00str00der is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, supports different size pulleys and belts for varying gear ratios, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users.<br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
Version 1.2 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v12<br />
<br />
Version 1.3 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v13<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
* hardware BOM has changed in version 1.2; refer to "Version History" section.<br />
* hardware BOM has changed in version 1.3; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Assembly instructions===<br />
A few people have put an 00str00der kit together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
The 00str00der has an (OpenSCAD) parametrized variant for a Bowden setup. In this variant the bore for the j-head is replaced with one that accommodates a press-to-fit connector. It also has mounting holes on the side for a right-angle attachment to a printer frame. Pictures of UConduit H-bot repraps show this setup in action.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody still needs to design a mount for other types of frame materials...<br />
<br />
=== Version History ===<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
==== Version 0.9 ====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
==== Version 1.0 ====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
==== Version 1.1 ====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
==== Version 1.2 ====<br />
Considered stable. Same as version 1.1 but with slightly modified idler for M4. No more M3 hardware, just M4 and M8 in BOM.<br />
<br />
The complete version 1.2 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v12 http://kitbom.com/terawattindustries/00str00der-extruder-v12].<br />
<br />
==== Version 1.3 ====<br />
Considered stable. Same as version 1.2 but with 65mm M8 knurled/hobbed bolt and 1x M8 jam nut. The M8 jam nut is for use between big pulley and 608 bearing to reduce hobbed bolt wobble. It should be hand-tightened against the 608 bearing on the big pulley side during assembly. Then the big pulley is pressed snugly against the jam nut and locked into place with its set screw.<br />
<br />
The complete version 1.3 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v13 http://kitbom.com/terawattindustries/00str00der-extruder-v13].<br />
<br />
=== Optional Parts ===<br />
==== JK Adapter Plate ====<br />
The adapter/mounting plate provides support for attaching the 00str00der to a Kuehling's compatible x-carriage, as described in "Upgrade/Retrofit". There are three (3) mounting holes for attaching the 00str00der to the plate. When using this setup, the extruder is rotated 90 degrees, perpendicular to the axis of motion. The plate can be machined or cast.<br />
<br />
==== 00dapter ====<br />
The 00dapter was added in 2014. The 00dapter provides compatibility for using an 00str00der with a Budaschnozzle. The 00dapter is based on the "Budapter" found on Thingiverse. It's intended to be used with the JK Adapter Plate. It is installed into the 00str00der grove-mount and fills the gap between the JK Adapter Plate and the Budschnozzle mount-plate.<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13650200str00der22014-11-28T02:13:49Z<p>Free: /* Direct-Drive Configuration */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assembly (with all including nuts, bushings, roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* M6 idler roller with 1x teflon bushing and 2x teflon washers<br />
* 6x M6 jam nuts<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der2 sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der2:<br />
# Use the 00str00der2 Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der2+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. NOTE: update required to PrismX for 00str00der2 mounting holes. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der2 with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der2 to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13650100str00der22014-11-28T02:11:18Z<p>Free: /* Non-Printed Parts */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assembly (with all including nuts, bushings, roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* M6 idler roller with 1x teflon bushing and 2x teflon washers<br />
* 6x M6 jam nuts<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13650000str00der22014-11-28T02:02:12Z<p>Free: /* 00str00der2 Idler Roller */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assembly (with all including nuts, bushings, roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13649900str00der22014-11-28T01:59:20Z<p>Free: /* 00str00der2 Idler Roller */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. Its time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assemble (with roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13649500str00der22014-11-28T01:58:04Z<p>Free: /* Background */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one or maybe I am confused -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. It's time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assemble (with roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13649400str00der22014-11-28T01:57:29Z<p>Free: /* Background */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear much faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a new tower design, even if just for aesthetics, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. It's time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assemble (with roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13649200str00der22014-11-28T01:53:47Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a tower design that wasn't like the original, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
* 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
* 1x M6 knurled bolt<br />
* 1x M6 idler bolt<br />
* 1x 00str00der2 idler roller<br />
* 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
* TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. It's time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assemble (with roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
* 60T GT2 pulley w/6mm bore<br />
* 16T GT2 pulley w/5mm bore<br />
* 90T GT2 belt w/2mm spacing<br />
* NEMA17 stepper motor<br />
* J-head hotend (for direct-drive)<br />
* (optional) Press-to-fit connector (for Bowden)<br />
* M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13648900str00der22014-11-28T01:51:18Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a tower design that wasn't like the original, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
A subtle but important difference in the new idler is the inverted mount -- in v.2 the idler is a male part and the block is a female part as this allows for more reinforcement in a tighter space.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Stronger idler fulcrum mount.<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
- 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
- 1x M6 knurled bolt<br />
- 1x M6 idler bolt<br />
- 1x 00str00der2 idler roller<br />
- 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
- TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. It's time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assemble (with roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
- 60T GT2 pulley w/6mm bore<br />
- 16T GT2 pulley w/5mm bore<br />
- 90T GT2 belt w/2mm spacing<br />
- NEMA17 stepper motor<br />
- J-head hotend (for direct-drive)<br />
- (optional) Press-to-fit connector (for Bowden)<br />
- M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13648600str00der22014-11-28T01:47:48Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_assembly_top.png<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a tower design that wasn't like the original, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
- 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
- 1x M6 knurled bolt<br />
- 1x M6 idler bolt<br />
- 1x 00str00der2 idler roller<br />
- 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
- TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. It's time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assemble (with roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00der2_tower_front.png|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00der2_idler_block.png|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00der13_jkmnt.png|200px|thumb|center|x-carriage mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
- 60T GT2 pulley w/6mm bore<br />
- 16T GT2 pulley w/5mm bore<br />
- 90T GT2 belt w/2mm spacing<br />
- NEMA17 stepper motor<br />
- J-head hotend (for direct-drive)<br />
- (optional) Press-to-fit connector (for Bowden)<br />
- M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=File:00str00der13_jkmnt.png&diff=136485File:00str00der13 jkmnt.png2014-11-28T01:47:24Z<p>Free: 00str00der adapter plate for mounting to Kuehling-style x-carriage.</p>
<hr />
<div>00str00der adapter plate for mounting to Kuehling-style x-carriage.</div>Freehttps://reprap.org/mediawiki/index.php?title=File:00str00der2_idler_block.png&diff=136482File:00str00der2 idler block.png2014-11-28T01:41:46Z<p>Free: 00str00der2 idler block with idler bolt and roller, OpenSCAD rendering, from side/above</p>
<hr />
<div>00str00der2 idler block with idler bolt and roller, OpenSCAD rendering, from side/above</div>Freehttps://reprap.org/mediawiki/index.php?title=File:00str00der2_tower_front.png&diff=136481File:00str00der2 tower front.png2014-11-28T01:40:05Z<p>Free: 00str00der2 OpenSCAD rendering, from front/above</p>
<hr />
<div>00str00der2 OpenSCAD rendering, from front/above</div>Freehttps://reprap.org/mediawiki/index.php?title=File:00str00der2_assembly_top.png&diff=136480File:00str00der2 assembly top.png2014-11-28T01:38:48Z<p>Free: OpenSCAD rendering of 00str00der2 from above.</p>
<hr />
<div>OpenSCAD rendering of 00str00der2 from above.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13647900str00der22014-11-28T01:36:42Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a tower design that wasn't like the original, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
- 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
- 1x M6 knurled bolt<br />
- 1x M6 idler bolt<br />
- 1x 00str00der2 idler roller<br />
- 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
- TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. It's time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assemble (with roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str002_tower_front.jpg|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str002_00idler.jpg|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str002_mntplate_jk.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
- 60T GT2 pulley w/6mm bore<br />
- 16T GT2 pulley w/5mm bore<br />
- 90T GT2 belt w/2mm spacing<br />
- NEMA17 stepper motor<br />
- J-head hotend (for direct-drive)<br />
- (optional) Press-to-fit connector (for Bowden)<br />
- M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13647800str00der22014-11-28T01:36:10Z<p>Free: /* Assembly instructions */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a tower design that wasn't like the original, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
- 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
- 1x M6 knurled bolt<br />
- 1x M6 idler bolt<br />
- 1x 00str00der2 idler roller<br />
- 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
- TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. It's time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assemble (with roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str002_tower_front.jpg|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str002_00idler.jpg|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str002_mntplate_jk.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
- 60T GT2 pulley w/6mm bore<br />
- 16T GT2 pulley w/5mm bore<br />
- 90T GT2 belt w/2mm spacing<br />
- NEMA17 stepper motor<br />
- J-head hotend (for direct-drive)<br />
- (optional) Press-to-fit connector (for Bowden)<br />
- M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
===How to make the hobbed bolt===<br />
TBD - separate page<br />
<br />
===How to make the idler===<br />
TBD - separate page<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=13647700str00der2014-11-28T01:34:44Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for the UConduit H-Bot 3D Printer with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs have converged (rev. C = 1.0) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]].<br />
<br />
The 00str00der is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, supports different size pulleys and belts for varying gear ratios, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users.<br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
Version 1.2 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v12<br />
<br />
Version 1.3 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v13<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
* hardware BOM has changed in version 1.2; refer to "Version History" section.<br />
* hardware BOM has changed in version 1.3; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Assembly instructions===<br />
A few people have put an 00str00der kit together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
The 00str00der has an (OpenSCAD) parametrized variant for a Bowden setup. In this variant the bore for the j-head is replaced with one that accommodates a press-to-fit connector. It also has mounting holes on the side for a right-angle attachment to a printer frame. Pictures of UConduit H-bot repraps show this setup in action.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody still needs to design a mount for other types of frame materials...<br />
<br />
=== Version History ===<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
==== Version 0.9 ====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
==== Version 1.0 ====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
==== Version 1.1 ====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
==== Version 1.2 ====<br />
Considered stable. Same as version 1.1 but with slightly modified idler for M4. No more M3 hardware, just M4 and M8 in BOM.<br />
<br />
The complete version 1.2 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v12 http://kitbom.com/terawattindustries/00str00der-extruder-v12].<br />
<br />
==== Version 1.3 ====<br />
Considered stable. Same as version 1.2 but with 1x M8 jam nut. The M8 jam nut is for use between big pulley and 608 bearing to reduce hobbed bolt wobble. It should be hand-tightened against the 608 bearing on the big pulley side during assembly. Then the big pulley is pressed snugly against the jam nut and locked into place with its set screw.<br />
<br />
The complete version 1.3 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v13 http://kitbom.com/terawattindustries/00str00der-extruder-v13].<br />
<br />
=== Optional Parts ===<br />
==== JK Adapter Plate ====<br />
The adapter/mounting plate provides support for attaching the 00str00der to a Kuehling's compatible x-carriage, as described in "Upgrade/Retrofit". There are three (3) mounting holes for attaching the 00str00der to the plate. When using this setup, the extruder is rotated 90 degrees, perpendicular to the axis of motion. The plate can be machined or cast.<br />
<br />
==== 00dapter ====<br />
The 00dapter was added in 2014. The 00dapter provides compatibility for using an 00str00der with a Budaschnozzle. The 00dapter is based on the "Budapter" found on Thingiverse. It's intended to be used with the JK Adapter Plate. It is installed into the 00str00der grove-mount and fills the gap between the JK Adapter Plate and the Budschnozzle mount-plate.<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der2&diff=13647600str00der22014-11-28T01:16:34Z<p>Free: Created page with "{{Development <!--Header--> |name = 00str00der2 |status = work in progress <!--Image--> |image = 00str00der2_firstever_1.JPG <!--General--> |description = The RepRap Wiki 00st..."</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der2<br />
|status = work in progress<br />
<!--Image--><br />
|image = 00str00der2_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der2 page.<br />
|license = BSD (revised, 3-clause)<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der2 is a bearing-free, belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a knurled or hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The 00str00der2 is created by Free Beachler, creator and owner of Longevity Software LLC d.b.a. Terawatt Industries. Based on the original 00str00der (version 1.3), it is entirely bearing-free, with a smaller bushing-based drive system; and is reinforced, redesigned, and re-coded.<br />
<br />
__TOC__<br />
==Summary==<br />
00str00der2 is a work in progress.<br />
<br />
The 00str00der2 is version 2 of the 00str00der belt-driven extruder.<br />
<br />
The 00str00der was originally conceived and designed in 2012. It is perhaps the most versatile and reliable extruder available on the market today. It offers an ultra-long-life design with GT2 pulleys and belts, and supports direct-drive and Bowden configurations. The design has been revised several times and proven in the field by Terawatt Industries and Reprap users. Now it is almost 2015 and it is time for major upgrades offered by 00str00der2.<br />
<br />
==Background==<br />
The original 00str00der has been revised several times by Terawatt Industries and has been proven in the field. A few issues have emerged:<br />
* Stress on the extruder tower (upper block) can cause breakage. It must be printed 100% solid.<br />
* Heat from hotend (direct-drive configuration) causes lubricants from bearings to drain. This drained lube may contribute to random hotend problems. The bearings wear faster than they would when cooler.<br />
* Wobble on the hobbed bolt. Corrected in version 1.3<br />
<br />
00str00der v2 attempts to address these issues and more in a bid for the perfect open source extruder design!<br />
<br />
The 00str00der2 is designed from the ground up. It looks similar to the original 00str00der, and it shares some of the original code, but overall this is a new/original design with nearly all original code and concepts. I spent a long time trying to think of a tower design that wasn't like the original, but ultimately I came back to the rectangle-shaped tower.<br />
<br />
There is no quick-release for the idler, again. I recently heard that Makerbot had filed a patent in 2014 alleging ownership over that seemingly open-source design, but no matter. I never intended a quick-release because the Greg's-style design -- apparently the patented one -- has never worked for me: it wears out and breaks the plastic, full stop, in all my experiences so far, which do not specifically include the patented design (disclaimer). Anyway I was thinking of something radically different for a quick-release - something derived from a bicycle quick-release for wheels, seat post, etc - if it ever happens it will probably be something quite different from the patent and quite clearly open-source, i.e. published here and Github or similar. This design will always be 100% open source.<br />
<br />
Major improvements in this design include:<br />
* Lube-free, bearing-free design<br />
* M6 acetal bushings<br />
* M6 knurled bolt<br />
* M6 idler bolt<br />
* Custom idler for 00str00der<br />
* Reinforced extruder base, tower, and motor mount<br />
* Same belt-driven design as original 00str00der<br />
* Increased motor adjustment freedom for belt tensioning<br />
<br />
==Mechanical Construction==<br />
TBD<br />
Assembly instructions will be similar to the original 00str00der, with a similar BOM, but M6 instead of M8. Idler roller assembly will be quite different though.<br />
<br />
Some instructions for idler roller assembly are provided in order to provide open source protection for this design.<br />
<br />
=== Materials ===<br />
TBD<br />
- 4x M6 self-aligning acetal bushings with flange, or non-self-align<br />
- 1x M6 knurled bolt<br />
- 1x M6 idler bolt<br />
- 1x 00str00der2 idler roller<br />
- 2x M3x12mm(?) socket cap screws for NEMA17 motor, with washers and lock washers<br />
- TBD M4 mounting hardware<br />
<br />
=== 00str00der2 Idler Roller ===<br />
The 00str00der2 introduces the concept of a custom idler roller for 3D printing. It's time is overdue, but this also presents significant acceptance and manufacturing challenges. To address this, the design and manufacturing process of the idler roller and idler bolt _must_ be 100% open source.<br />
<br />
The idler roller is already designed in OpenSCAD but it is a WIP. Open source manufacturing instructions are TBD.<br />
<br />
The idler roller is made from brass, aluminum, or steel, in order of preference. It is approximately 20mm in diameter and 5mm thick. It is knurled and grooved, with a smooth <1mm groove, thus creating a smooth trough and rough saddle. The groove can be any shape, can be smooth, completely rough, or partially smooth and/or rough. The idler roller has a 12mm bore which accommodates a teflon or acetal/delrin bushing with ~12mm diameter and ~5mm thickness. The teflon bushing has a 6mm bore for an M6 bolt. The teflon bushing is also manufactured with a pair of teflon washers that are assembled on either side of the bushing.<br />
<br />
The M6 bolt is fully threaded. One set of metal M6 washer, M6 nut, and M6 jam nut are assembled on each side of the teflon washers, with metal washers next to teflon washers, then tightened to hand. The bolt assemble (with roller) is inserted into a slot in the idler and affixed with nuts on either side of the idler.<br />
<br />
=== M6 Knurled Bolt ===<br />
00str00der2 is designed for an M6 knurled bolt. The bolt has excellent grip and is lighter than the M8 counterpart. Perhaps someday we will design an M8 variant or go back to M8 but first we'll see how M6 does in the field.<br />
<br />
The M6 knurled bolt is not necessarily precise, but it typically is within the M6 diameter by +/-0.2mm(?).<br />
<br />
==== Printed Parts ====<br />
The 00str00der tower and idler have been completely redesigned. Reinforcements have been added to the design everywhere while attempting to maintain a similar form factor. We do not know if 100% solid infill is required yet, it might not be with a thick shell and hollow inside.<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str002_tower_front.jpg|200px|thumb|center|00str00der2 block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str002_00idler.jpg|200px|thumb|center|00str00der2 idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str002_mntplate_jk.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
- 60T GT2 pulley w/6mm bore<br />
- 16T GT2 pulley w/5mm bore<br />
- 90T GT2 belt w/2mm spacing<br />
- NEMA17 stepper motor<br />
- J-head hotend (for direct-drive)<br />
- (optional) Press-to-fit connector (for Bowden)<br />
- M4 mounting hardware (TBD)<br />
<br />
===3D CAD Files===<br />
The OpenSCAD files have been completely overhauled. Most are coded from scratch. Only two have been revised from the original version, 00functions.scad and 00configuration.scad.<br />
<br />
===Assembly instructions===<br />
TBD<br />
<br />
=== Upgrade/Retrofit ===<br />
Backwards compatibility was abandoned on this design long ago, and the new drive system is very different. The only parts that can be kept are the motor, small pulley, and some M4/M3 mounting hardware. The rest will have to be obtained separately.<br />
<br />
==== Direct-Drive Configuration ====<br />
TBD<br />
<br />
==== Bowden Configuration ====<br />
00str00der2 will support the same press-to-fit connectors as the original 00str00der. It will also support a right-angle mounting setup for Bowden just like the original. This is all WIP.<br />
<br />
=== Version History ===<br />
<br />
==== Version 2.0 ====<br />
<br />
=== Optional Parts ===<br />
<br />
==== JK Adapter Plate ====<br />
The adapter plate is based on the version 1.3 mountplate. It is a WIP and will be revised for modified mount hole and hotend positions.<br />
<br />
==== 00dapter ====<br />
The 00dapter can still be used in v2 for a modified setup with the budaschnozzle.<br />
<br />
==Extruder Calibration==<br />
<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M6 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch. If the bolt is knurled then its diameter will typically be very close to the diameter of an M6 bolt ~= 6mm.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=13645500str00der2014-11-27T23:25:39Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for the UConduit H-Bot 3D Printer with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Assembly instructions===<br />
A few people have put an 00str00der kit together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
=== Version History ===<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
==== Version 0.9 ====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
==== Version 1.0 ====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
==== Version 1.1 ====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
=== Optional Parts ===<br />
==== JK Adapter Plate ====<br />
The adapter/mounting plate provides support for attaching the 00str00der to a Kuehling's compatible x-carriage, as described in "Upgrade/Retrofit". There are three (3) mounting holes for attaching the 00str00der to the plate. When using this setup, the extruder is rotated 90 degrees, perpendicular to the axis of motion. The plate can be machined or cast.<br />
<br />
==== 00dapter ====<br />
The 00dapter was added in 2014. The 00dapter provides compatibility for using an 00str00der with a Budaschnozzle. The 00dapter is based on the "Budapter" found on Thingiverse. It's intended to be used with the JK Adapter Plate. It is installed into the 00str00der grove-mount and fills the gap between the JK Adapter Plate and the Budschnozzle mount-plate.<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=13645400str00der2014-11-27T23:25:07Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Bowden Extruder}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for the UConduit H-Bot 3D Printer with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Assembly instructions===<br />
A few people have put an 00str00der kit together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
=== Version History ===<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
==== Version 0.9 ====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
==== Version 1.0 ====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
==== Version 1.1 ====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
=== Optional Parts ===<br />
==== JK Adapter Plate ====<br />
The adapter/mounting plate provides support for attaching the 00str00der to a Kuehling's compatible x-carriage, as described in "Upgrade/Retrofit". There are three (3) mounting holes for attaching the 00str00der to the plate. When using this setup, the extruder is rotated 90 degrees, perpendicular to the axis of motion. The plate can be machined or cast.<br />
<br />
==== 00dapter ====<br />
The 00dapter was added in 2014. The 00dapter provides compatibility for using an 00str00der with a Budaschnozzle. The 00dapter is based on the "Budapter" found on Thingiverse. It's intended to be used with the JK Adapter Plate. It is installed into the 00str00der grove-mount and fills the gap between the JK Adapter Plate and the Budschnozzle mount-plate.<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=13012700str00der2014-07-24T07:24:47Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for the UConduit H-Bot 3D Printer with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Assembly instructions===<br />
A few people have put an 00str00der kit together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der onto the adapter plate using the 3-point mounting holes.<br />
### Note the recessed holes (on bottom of plate) to accommodate two (2) M4x30mm socket cap screws; these are for the socket-cap screw heads. The screw heads must not protrude from the bottom of the plate so the plate can mount flush to the x-carriage.<br />
### The third mounting point is one (1) M4x16mm low-head socket cap screw, underneath the motor. The nut is on the bottom of the plate here - reverse of the M4x30mm mounting screws. This screw can protrude from the bottom.<br />
## Attach 00str00der+plate to a compatible x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. Perhaps the best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der with idler arm, hobbed bolt, pulley motor, hotend, and all.<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one. Steps for this procedure depend on the type of 3D printer and are beyond the scope of this article.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
=== Version History ===<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
==== Version 0.9 ====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
==== Version 1.0 ====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
==== Version 1.1 ====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
=== Optional Parts ===<br />
==== JK Adapter Plate ====<br />
The adapter/mounting plate provides support for attaching the 00str00der to a Kuehling's compatible x-carriage, as described in "Upgrade/Retrofit". There are three (3) mounting holes for attaching the 00str00der to the plate. When using this setup, the extruder is rotated 90 degrees, perpendicular to the axis of motion. The plate can be machined or cast.<br />
<br />
==== 00dapter ====<br />
The 00dapter was added in 2014. The 00dapter provides compatibility for using an 00str00der with a Budaschnozzle. The 00dapter is based on the "Budapter" found on Thingiverse. It's intended to be used with the JK Adapter Plate. It is installed into the 00str00der grove-mount and fills the gap between the JK Adapter Plate and the Budschnozzle mount-plate.<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder.<br />
<br />
[[Category:Working Extruders]]</div>Freehttps://reprap.org/mediawiki/index.php?title=PCB_Heatbed&diff=120061PCB Heatbed2014-03-16T11:10:55Z<p>Free: /* FORKS (not done by Prusa) */</p>
<hr />
<div>{{Development<br />
|description = PCB Heatbed<br />
|status = working<br />
|author = Josef Průša<br />
|reprap = mendel/darwin/repstraps<br />
|cadModel = [[http://www.thingiverse.com/thing:3919]]<br />
|categories = [[Category:Heated Bed]]<br />
|image = PCB_HEATBED.jpg<br />
|url = http://josefprusa.cz/pcb-heatbed-final-mounting-and-wiring-solutio<br />
}}<br />
<br />
==WARNING==<br />
<span style="color:red;>"'''WARNING!!!'''<br />
Be aware from where you buying the PCB heatbeds!!<br />
There is one critical thing, the heatbed must be etched directly from 35um copper clad! ASK YOUR SELLER!!!<br />
If the board is plated, as it's normally done, no manufacturer can guarantee the final thickness of copper or how even the copper is around the board.<br />
Which means that the final power wont be evenly distributed around the board or the board wont have high enough output generally. <br />
<br />
'''Main warning sign are plated holes! Plating of holes requires copper plating.'''<br />
<br />
</span><br />
<br />
==About==<br />
<br />
PCB Heatbed MK1 is developed by [[User:Prusajr | Josef Průša]]<br />
<br />
* 200 mm x 200 mm active heated area<br />
* 209 mm center-to-center mounting holes (outside the active area).<br />
* 214 mm x 214 mm total PCB size<br />
<br />
I was working on this idea for nearly six months, inspired by [http://neufeld.newton.ks.us/electronics/?p=864 neufeld.newton.ks.us/electronics/?p=864 ].<br />
<br />
==Where to get it==<br />
[[Category:Suppliers_by_Part]]<br />
<br />
The .brd file is available here: [[http://www.thingiverse.com/thing:3919]]<br />
<br />
Mechanical drawings for designing mounting plates/etc (if desired) are here: [[http://www.thingiverse.com/thing:21271]]<br />
<br />
(Please note that I dont get any provision from these :-))<br />
Manufactured PCBs can be found here:<br />
<br />
=== Asia ===<br />
<br />
[http://www.robotdigg.com/product/99/MK2B-Heatbed RobotDigg]<br />
<br />
Reprap Austria http://www.reprap.cc<br />
<br />
3D Acessories Hub (IN ,Worldwide) http://www.3dacessorieshub.com <br />
<br />
[http://reprapdiscount.ecwid.com/simple-store#ecwid:category=2855167&mode=product&product=12583494 Reprapdiscount Hong Kong and Worldwide]<br />
<br />
[http://cgi.ebay.ca/ws/eBayISAPI.dll?ViewItem&item=171039945755&ssPageName=STRK:MESE:IT Botech Circuits China and Worldwide]<br />
<br />
[http://makemendel.com/mechanical-parts/electronics-parts/pcb-heatbed Makemendel]<br />
<br />
[http://3dprinterczar.com/shop/electronics/pcb-heatbed-mk2a/ 3D Printer Czar Hong Kong]<br />
<br />
[http://www.reprap.cn/the-reprap-3d-printer-heating-bed-pcb-heatbed-mk2a-p-26.html He3D]<br />
<br />
=== EU ===<br />
<br />
Print All the Things!!! (Spain,Europe) http://www.printallthethings.com/en/heat-bed/45-heatbed-mk2b.html<br />
<br />
Think3dPrint3d (UK, Worldwide) http://www.think3dprint3d.com/Electronics/PCB-Heatbed-MK2a<br />
<br />
Reprap Austria http://www.reprap.cc<br />
<br />
3Distributed (UK, Worldwide) http://www.3distributed.com/collections/electronics<br />
<br />
ReprapUniverse.com (Netherlands, Worldwide) http://reprapuniverse.com/catalog/product_info.php?cPath=74&products_id=39 (MK2a - New improved design - 214 x 214 mm)<br />
<br />
RepRap.me (Denmark, Worldwide) http://reprap.me/kits/pcb-deluxe-kit.html (Two color ruler design MK2 heatbed and MK3 ALU-Heatbed)<br />
<br />
Menextech (Spain, Worldwide) http://www.menextech.com/shop<br />
<br />
Charlie's 3D Technologies (Belgium, Worldwide) http://www.charlies3dtechnologies.eu/<br />
<br />
GADGETS3D (Poland, Worldwide) http://gadgets3d.com/index.php?route=product/product&product_id=68<br />
<br />
RepRapSource (Germany) http://www.reprapsource.com/en/shop/show/6403<br />
<br />
eMotion Tech (France) http://www.reprap-france.com/lit-chauffant-et-accessoires/10-pcb-heatbed.html<br />
<br />
Cubic Print (Germany) http://www.cubic-print.com/PCB-heated-bed<br />
<br />
LHPPortugal(Portugal) http://www.lhpportugal.com/loja/index.php?route=product/product&product_id=193<br />
<br />
Paoparts (France) http://www.paoparts.com/fr/200-plaque-chauffante-mk2a.html<br />
<br />
Robots3D (Russia, Worldwide) http://robots3d.ru/parts_accessories/heated_beds/heatbed_mk2a_pcb.html<br />
<br />
uw3Dprinter.nl -ONLY MK2-(Netherlands, Worldwide) http://www.uw3dprinter.nl/en/heatbed-mk2.html<br />
<br />
Createc 3D (Spain, Worldwide) http://shop.createc3d.com<br />
<br />
=== USA ===<br />
<br />
[http://3dbotshack.com/3dprinterpcbheatbed.html 3dBotShack]<br />
<br />
[http://www.makergear.com/products/3d-printers MakerGear]<br />
<br />
[http://www.lulzbot.com/en/14-heated-print-bed.html Lulzbot]<br />
<br />
[http://ultimachine.com/content/prusa-pcb-heated-bed Ultimachine]<br />
<br />
[http://www.makerfarm.com/index.php/printer-electronics/heatbed-mk1.html MakerFarm]<br />
<br />
[http://www.reprap-usa.com/index.php?route=product/product&product_id=51 RepRap-USA]<br />
<br />
[http://3dprinterczar.com/product-category/3dprinter_parts/electronics/ 3D Printer Czar-USA]<br />
<br />
==Printing==<br />
<br />
<br />
Cover the bed with kapton tape. Degrease it and print.<br />
<br />
ABS temp: 110°C<br />
PLA temp: 50-60°C<br />
<br />
MAKE SURE YOUR [[Power Supply]] HAS 10 MORE AMPS SPARE!!!<br />
<br />
<br />
==Mounting==<br />
<br />
<br />
Known working solution, I (prusajr) use is Glass sheet (3mm) with glued on cork standoffs and on top of that is glued the heatbed.<br />
http://www.flickr.com/photos/prusajr/5410919911/<br />
http://www.flickr.com/photos/prusajr/5410919707/<br />
<br />
<br />
When mounted only using the four corners, the inherent warp of the pcb can be a problem, hence it is better to use the cork mounting system above (as the piece of cork in the centre helps to keep the pcb flat).<br />
Magnets can be used in replace of the cork, this makes the bed removable. However, I (mooneyj) have only tried this on a darwin type printer (where the build platform only moves in z). During fast printing, the darwin vibrates and it seems the heatbed magnets slide over each other slightly. The acceleration of the y axis on a mendel may cause the magnets to slide also. Perhaps a hybrid of magnet and bolt mounting would work well?.<br />
<br />
<br />
The current standard, however, is to simply place the glass on top of the heatbed, and affix it on the four sides with bulldog clips. The clips will not melt under pressure, and sufficiently hold the glass to the bed. This makes removal more easily for cleaning as well.<br />
<br />
'''Note''': According to the Eagle file posted on Thingiverse, the M3 holes are spaced 209 mm<br />
<br />
Mechanical drawings are here: [[http://www.thingiverse.com/thing:21271]]<br />
<br />
==Sides==<br />
<br />
PCB Bed has two sides, one with the traces (bottom side) and one with silkscreen (top).<br />
<br />
Printing on top side is safer, works great.<br />
<br />
Printing on bottom is more effective and heats up quicker. (Though the LED, resistor and wire connections are liable to collision with the print head. Also the tracks could be damaged if the print head collides. Make sure your z-bed-springs are not too strong to prevent damage during a collision).<br />
<br />
[[File:PCB_HEATBED.jpg]]<br />
<br />
==Connection==<br />
<br />
<br />
===Optional LEDs===<br />
<br />
The LEDs are optional, but if you choose to use the LEDs you MUST install the resistor.<br />
<br />
''''Parts''''<br />
<br />
2 x Surface Mount LEDs<br />
<br />
1 x 1K ohm Surface Mount Resistor<br />
<br />
<br />
<br />
Mount the LEDs in different directions (polarity) so that one of the LEDs will light up regardless of the board's polarity. You can use a single LED if you are certain of the polarity.<br />
<br />
[[File:PCB_HEATBED_DIAGRAM_r.jpg]]<br />
<br />
===Electronics===<br />
''RAMPS''<br />
<br />
See [[RAMPS1.4]], [[RAMPS1.3]], or [[RAMPS1.2]] depending on your version.<br />
<br />
''Sanguinolou''<br />
The MK2 PCB heatbed heats up to 110C when powered through the heated bed connection on Sanguinolou, your power supply should be 300W and ensure your wires from your power supply to the Sanguinololu should be capable of handling the total draw of 20A+. Using a 300W ATX power supply with the 4wire ATX dual 12V connector is working well for me.<br />
<br />
N.B. It is recommended that you use a heatsink on your heated bed mosfet, it will get hot!<br />
<br />
N.B. It is recommended that you measure the resistance of your board. I (evilB) didn't and blew up my Ramps 1.2 MOSFET because of a too high current. My measured resistance was 0.8 Ohm.<br />
<br />
==Testing==<br />
<br />
Its now in working state, Printed load of kits on it, working great.<br />
<br />
<br />
Main Idea is to use resistance of pcb traces as heating element.<br />
<br />
The following video shows a PCB heatbed MK2 being heated to 60 degrees as seen by an infrared camera:<br />
<videoflash>QE90bDUaAno</videoflash><br />
<br />
==Thermal insulation==<br />
<br />
It's a good idea to insulate the underside of the heatbed in order to get a faster heat up time and a overall better thermal performance.<br />
<br />
[[File:Thermal_Isolation.png]] <br />
<br />
<br />
The MK2 / MK3 Thermal Insulator is a great way to do exactly that. <br />
<br />
Mount the gasket firmly under the heatbed for the best thermal isolation.<br />
<br />
It fits the standard heatbed size of the 214mm x 214mm (200mm x 200mm) MK2 and MK3.<br />
<br />
<br />
<br />
Material: Cork<br />
<br />
Thickness: 2mm<br />
<br />
==== Where to get it ====<br />
<br />
[http://reprap.me/mk2-mk2-thermal-insulator.html www.RepRap.me]<br />
<br />
== FORKS (not done by Prusa)==<br />
<br />
=== MK2, MK2a ===<br />
<br />
It's not successor of MK1 even with it's name. It's concurrent design. - Josef Prusa<br />
<br />
MK2a Heatbed with minor changes by Tony from [http://www.think3dprint3d.com/ Think3dPrint3d]<br />
<br />
==== About the MK2a ====<br />
<br />
I liked Josef's original design but wanted to be able to use through hole components, have the thermistor poke through the middle and for it to look good on the 'back' with the silkscreen that Josef designed on that side as well.<br />
<br />
The MK2a has a few further changes:<br />
<br />
* A mounting hole in the middle of one edge to allow for easier bed levelling, thanks to [http://hydraraptor.blogspot.com/2012/05/bed-levelling.html Nophead] for this suggestion.<br />
* Larger LED and Resistor pads to allow for 1206 size surface mount components.<br />
* Much larger area to solder the current carrying wire, easily connect ribbon cable (such as with the Mendel90 heatbed connection). Also the through holes increased in size.<br />
* The redundant pads on the non-heating element side of the board removed to prevent confusion. These are not electrically connected if the board is not plated (plated boards are bad for the reasons outlined by Josef Prusa above).<br />
<br />
==== Further update of the MK2a ====<br />
(by Tony from [http://www.think3dprint3d.com/ Think3dPrint3d])<br />
<br />
In order to make ribbon cable easier to use we have made the following changes:<br />
<br />
Holes in the extended solder pads<br />
<br />
[[File:MK2a-header_holes.jpg | 600px]]<br />
<br />
This allows for IDC compatible pin headers to be used <br />
<br />
[[File:MK2a-headers.jpg | 600px]]<br />
<br />
This in turn makes plugging in a heated bed wiring loom very easy<br />
<br />
[[File:MK2a-headers_connectors.jpg | 600px]]<br />
<br />
==== Where to get it ====<br />
<br />
The MK2 .brd file is available here: [[File:PCB_heatedbed_Mk2.brd]]<br />
<br />
The MK2a .brd file is available here [[File:PCB_heatedbed_Mk2a.brd]]<br />
<br />
Manufactured MK2 PCBs can be found here:<br />
<br />
[http://www.think3dprint3d.com/Electronics/PCB-Heatbed-MK2a Think3dPrint3d (UK, Worldwide)]<br />
<br />
[http://www.reprap-france.com/lit-chauffant-et-accessoires/10-pcb-heatbed.html eMotion Tech - Fully soldered and wired]<br />
<br />
[http://www.3distributed.com/products/mk2-heated-bed-1 http://www.3distributed.com/products/mk2-heated-bed-1]<br />
<br />
[http://www.charlies3dtechnologies.eu www.charlies3dtechnologies.eu]<br />
<br />
[http://gadgets3d.com/index.php?route=product/product&product_id=59 www.gadgets3d.com]<br />
<br />
[http://reprap.me/electronics/reprap-pcb-heatbed-mk2.html www.RepRap.me]<br />
<br />
[http://stores.ebay.ca/botechengineeringpcbservice Botech Circuits MK2a]<br />
<br />
[http://www.ebay.co.uk/sch/i.html?_nkw=heatbed+reprap+MK2a&_sacat=See-All-Categories#ptm eBay MK2a]<br />
<br />
[http://www.emakershop.com/browse/listing?l=126 eMakerShop MK2a]<br />
<br />
[http://stores.ebay.com/reprapdiscount Reprapdiscount MK2 and MK2a eBay]<br />
<br />
[http://www.paoparts.com/fr/200-plaque-chauffante-mk2a.html Paoparts (fr) MK2a]<br />
<br />
[http://www.cubic-print.com/PCB-heated-bed-MK2 Cubic Print (Germany)]<br />
<br />
[http://www.uw3dprinter.nl/en/heatbed-mk2.html Uw3Dprinter.nl MK2 (NL,BE,DE,FR)]<br />
<br />
[http://www.reprap.cn www.reprap.cn]<br />
<br />
==== Printing ====<br />
'''MK2'''<br />
<br />
Although you can print directly to the bed covered in polyimide tape, no PCB is perfectly flat. It is recommended that you follow the directions in mounting, below, for better results.<br />
<br />
==== Mounting ====<br />
'''MK2'''<br />
<br />
The MK2 board can be mounted either side up and is designed to be mounted as Josef describes:<br />
<br />
http://josefprusa.cz/pcb-heatbed-final-mounting-and-wiring-solutio<br />
<br />
The holes in the 4 corners to attach the heated bed MK2 to the top print plate are not suitable for M3 bolts though! Use M2.5 instead.<br />
<br />
The glass protects the tracks from a head crash and is easily swapped out.<br />
<br />
The board dimensions are identical to the MK1 design.<br />
<br />
Insulation between the board and the thick plate should improve heat-up times and reduce energy consumption. An example is here:<br />
<br />
http://reprap.org/wiki/Mendel_heated_bed#Thermal_Insulation<br />
<br />
''Caution, I have not tried this with the temperatures that the PCB bed can reach!''<br />
<br />
'''MK2a'''<br />
<br />
The MK2a has a central mounting hole on the front side to allow for three point mounting. This is much easier for bed leveling in comparison to 4 point mounting. First level the side with two holes and fix in place, then level the side with one hole. A glass plate is highly recommended to provide a truly flat surface and rigidity.<br />
<br />
[[File:Mk2a_Central_Mount_Point.jpg |200 px]]<br />
<br />
====Sides====<br />
'''MK2'''<br />
<br />
The PCB still has a side with the traces on and a side without but now the silkscreen is on both the top and bottom, this makes it look good even when 'upside down' under a layer of glass. The LED, resistor and power wires can be mounted on either side of the board, with either surface mount or through hole components. If you are using through hole be careful when soldering not to interfere with the glass and introduce a gap between the glass and the PCB. If the MK2 board is made properly without copper plating then be sure to only solder the LED and resistor to the same side and the tracks. This problem is solved in the MK2a by removing the pads on the non connected side.<br />
<br />
MK2<br />
[[File:PCB_Heatbed_MK2_front_small.jpg| 400px]]<br />
<br />
<br />
MK2a<br />
[[File:Mk2a.jpg| 400px]]<br />
<br />
<br />
MK2b Dual Power<br />
[[File:RRD-Mk2b-dual-power.jpg| 400px]][[File:RRD-Mk2b-dual-power_blk.jpg| 445px]]<br />
<br />
There is a central hole in the board and it is sized so a small thermistor<br />
(for example the EPCOS one: http://uk.farnell.com/jsp/search/productdetail.jsp?CMP=i-ddd7-00001003&sku=3878697 ) will fit though it allowing contact directly with the glass.<br />
''todo: test efficacy of using heat sink compound to better thermally couple the thermistor to the glass''<br />
<br />
[[File:PCB_Heatbed_MK2_therm_hole.jpg| 200px]]<br />
<br />
====Connection====<br />
Polarity doesn't affect the PCB, however the LEDs have a polarity.<br />
<br />
'''MK2'''<br />
<br />
There are pads and un-plated through holes for connecting the power wires. Ensure that the wire you use is thick enough for 10A, and solder it to the pads on the track side of the PCB. It is a good idea to think about strain relief so your moving build platform does not flex the joint, this can lead to failure of the joint over time. I recommend routing the wire from the heated bed to strain relief on the thick sheet before routing it to your controller/power supply. ''todo: get pictures of strain relief''<br />
<br />
'''MK2a'''<br />
<br />
The pads to solder onto have been greatly increased as shown in the picture below. The picture shows the wires prepared for soldering routed through the holes for extra security. This does not remove the need to use proper strain relief.<br />
<br />
[[File:Mk2a_Through_Hole.jpg|400 px]]<br />
<br />
'''MK2b Dual Power'''<br />
<br />
As you can see in the pictures below depending on the voltage you want to use you have to use different solder pads, but it's written on the PCB which pads have to be used for which voltage.<br />
<br />
[[File:RRD-Mk2b-dual-power-table.jpg|400px]] [[File:RRD-Mk2b-dual-power-connector_red_blk.jpg|400px]]<br />
<br />
'''MK2i'''<br />
The MK2i is connected just like the MK2a heatbed.<br />
<br />
=====Optional LEDs=====<br />
'''MK2'''<br />
<br />
The LEDs are optional, but if you choose to use the LEDs you MUST install the resistor. Solder the components to the pads on the track side of the PCB. With the MK2, conventional wired parts can be substituted for the surface mount parts. If your MK2 board is made properly without copper plating then be sure to only solder the LED and resistor to the same side and the tracks. This problem is solved in the MK2a by removing the pads on the non connected side.<br />
<br />
<br />
''''Parts''''<br />
<br />
2 x surface mount (0805 size on the MK1 and MK2, 1206 size on the MK2a for easier soldering) or conventional through-hole LEDs. Install with opposite polarity so one or the other will light up regardless of the polarity of the power supply to the board.<br />
<br />
1 x 1K ohm surface mount or through-hole resistor<br />
<br />
=== MK2b Dual Power Technical Details===<br />
You can find the open source files here: http://forum.reprapdiscount.com/forums/oss/<br />
<br />
* Dimensions 214mmx 214mm<br />
* Laminate FR4 1.6+-0.15mm<br />
* 2 layer, 35μm copper<br />
* Red Soldermask - both sides<br />
* White Silkscreen - both sides<br />
* Power Input: 12V or 24v<br />
* copper plated holes<br />
* resistance between 1.0-1.2 ohm (12V) or 3-3.4 ohm (24V) (Sainsmart board came in at 1.8 ohm @ 12V/3.6 ohm @ 24V)<br />
<br />
Very good in combination with [[RUMBA]] or [[Taurino#Taurino_Power|Taurino Power]]<br />
<br />
=== MK2i ===<br />
[[File:IMG_8284_smnocopy.png|400px]]<br />
[[File:IMG_8271_smnocopy.png|400px]]<br />
<br />
The MK2i is a hybrid of MK2a and MK3 designs. It supports 4-point and 3-point mounting. There is a central hole in the PCB for a through hole thermistor such as EPCOS. There are also pads on top and bottom for an SMD or through-hole thermistor. The pads are on the top/bottom (in the center of the PCB, next to the hole) but the thermistor trace is on the top copper and routes again to the bottom for easier wiring, labelled "NTC". This design is versatile and much less tape is needed for strain relief on the thermistor wires.<br />
<br />
The MK2i also sports an internationalized stencil on top and bottom. The stencil has new international symbols for "hot" and "hot - do not touch", as well as translations in English, Spanish, French, and German. The original CAD file also had translations in Chinese, Russian, Arabic, and Japanese - but it fails to export these character sets so they aren't in the final version.<br />
<br />
The code is at [https://github.com/Terawatt-Industries/mk2i https://github.com/Terawatt-Industries/mk2i] and comes with a LBR library file. You should be able to have PCBs made from the MK2i Gerbers. It's probably feasible to make this by hand - as much as an MK2a PCB - except in this case you must have bottom and top layers if you want the thermistor wiring feature.<br />
<br />
== MK2 A4 ==<br />
<br />
This is [[Clone_Wars:_Othon | my build]]. I always wanted a big bed, in order to be able to plot (yes, actually plot, with artistic purpouses) at least DIN A4 in size. So I built my prusa mendel big enough to be able to host such a HBP PCB. I'm no good with any PCB editor, so I made my files in a CAD program, and exported the result file into a dxf file. The file has several layers the names of which should make the information self understandable. Anyway I'll tell: the layers with number names represent the routing of the traces the width of which is the layer's name in mm. The design was basically copied from MK2a. The engineering was made with an evolutive algorithm developed by [[Clone_Wars:_Othon | Damrod]] in [http://www.grasshopper3d.com/ grasshopper]. The manufacturing was a bit faulty, but it works flawlessly.<br />
<br />
* Dimensions 215mmx 315mm<br />
* 1 layer 35μm copper<br />
* resistance between 1.0 and 1.2 ohm<br />
<br />
[[File:Big_Heatbed.JPG|600 px]]<br />
<br />
[https://dl.dropbox.com/u/6334877/heatbed%20mejor.dxf source dxf]<br />
<br />
== PCB Heatbed 200X300mm ==<br />
<br />
<br />
<br />
[[file:200X300.jpg|600 px]]<br />
[[file:200X300-TOP.jpg|600 px]]<br />
<br />
The PCB Heatbed 200X300mm has a 100mm bigger built area then the regular MK2 heatbed and the overall outline is 214X314mm.<br />
<br />
It has dual power mode optimized for 12 or 24V but you can also use everything in between (16V, 19V what have you)<br />
(Your printer controller will regulate the power to the heatbed in order to get your preset temperature.)<br />
<br />
The core is regular 1.6mm FR4 PCB and the print surface is the same as regular heatbeds but with a metric ruler grid. <br />
<br />
The connections to the heatbed is the same as the connections on the MK3 Alu. heatbed belov.<br />
<br />
The PCB Heatbed 200X300mm is now available in the [http://reprap.me/ RepRap.me] webshop. <br />
<br />
* Dimensions 214mm x 314mm<br />
* 1 layer 35μm (1oz base) copper<br />
* Resistance between 1 and 1.3 ohm for the 12V<br />
* Resistance between 4.5 and 5 ohm for the 24V<br />
* 110 degrees Celsius possible for both 12V and 24V<br />
* Running 24V on the 12V terminals will heatup the heatbed to 100 degree in only 2 minutes<br />
* 180 degree Celsius max. temperature<br />
<br />
== MK3 ALU-Heatbed Dual Power ==<br />
<br />
The [http://reprap.me/Alu-Heatbed-MK3 Alu-Heatbed MK3] have features similar to MK2 and you can also operate this board with 12V or 24V.<br><br />
<br />
- Heatbed with 3.2mm Aluminum Core. Print directly on the heatbed, no need for glass plate. It's a much lighter solution than PCB heatbed + glass, which makes it better for faster prints.<br><br />
- Dual power supply. Operate at 12V or 24V. You can use thinner wires when operating at 24V.<br><br />
- A central mounting hole on the front side to allow for three point mounting. This is much easier for bed leveling in comparison to 4 point mounting. First level the side with two holes and fix in place, then level the side with one hole.<br><br />
- Large solder pads for multiple wires (ribbon cable) or a SMD pinhead connector can be mounted.<br><br />
- Pads for SMD thermistor 1206<br><br />
<br />
* Dimensions 214mm x 214mm<br />
* 1 layer 35μm (1oz base) copper<br />
* Resistance between 1.4 and 1.6 ohm for the 12V<br />
* Resistance between 5.0 and 5.4 ohm for the 24V<br />
* 100 degree Celsius possible for both 12V and 24V<br />
* With 15V on the 12V terminals will maintain approx. 115 degree Celsius without regulation<br />
* Running 24V on the 12V terminals will heatup the heatbed to 100 degree in only 2 minutes (Your printer controller will regulate the power to the heatbed in order to get your preset temperature.)<br />
* 180 degree Celsius max. temperature<br />
<br />
[[File:alu_heatbed.JPG|600 px]]<br />
''' Bottom side (Do not print directly on this side)'''<br />
<br />
[[file:Alu TOP .jpg|600 px]]<br />
''' Top side (Printing side) '''<br />
<br />
[[File:Alu 12V small.jpg|300 px]]<br />
[[File:Alu 24V small.jpg|300 px]]<br />
<br />
Recommended NTC: EPCOS - B57621C104J62 - THERMISTOR, 100K "or whatever [[thermistor]] you normally use."<br />
<br />
==== Where to get it ====<br />
<br />
[http://reprap.me/electronics/alu-reprap-heater-board-mk3.html www.RepRap.me]<br />
<br />
== MK2a layout in SVG-format ==<br />
<br />
There's an SVG-version (Inkscape) of the MK2a-layout.<br />
<br />
For the toner transfer method and people that only have a printer for letter/DIN A4 there's a version with two separated parts.<br />
Because the parts only have few electrical contacts between them, they easily can be ironed next to each other, fixing the needed bridges with etch resistant paint before etching.<br />
<br />
<gallery><br />
File:Layout_Heatbed_MK2a.svg|MK2A in SVG<br />
File:Layout_Heatbed_RK1_parts_a_b.svg|Printer friendly Part I<br />
File:Layout_Heatbed_RK1_parts_c_d.svg|Printer friendly Part II<br />
File:All_breaches_fixed.JPG|Toner transfered and ready to etch<br />
File:Etched and ready.JPG|The etched board<br />
</gallery><br />
<br />
(You may follow the complete process here: [[Etched_heatbed_construction]])</div>Freehttps://reprap.org/mediawiki/index.php?title=File:IMG_8284_smnocopy.png&diff=120060File:IMG 8284 smnocopy.png2014-03-16T11:05:57Z<p>Free: MK2i PCB Heated Build Platform - LEDs, resistor, and solder pads; bottom side</p>
<hr />
<div>MK2i PCB Heated Build Platform - LEDs, resistor, and solder pads; bottom side</div>Freehttps://reprap.org/mediawiki/index.php?title=File:IMG_8271_smnocopy.png&diff=120059File:IMG 8271 smnocopy.png2014-03-16T11:03:02Z<p>Free: MK2i PCB Heated Build Platform - center hole and thermistor pads</p>
<hr />
<div>MK2i PCB Heated Build Platform - center hole and thermistor pads</div>Freehttps://reprap.org/mediawiki/index.php?title=PCB_Heatbed_MK2i&diff=120020PCB Heatbed MK2i2014-03-15T04:47:01Z<p>Free: Redirected page to PCB Heatbed</p>
<hr />
<div>#REDIRECT [[PCB_Heatbed]]</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11424500str00der2014-01-01T21:53:09Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Assembly instructions===<br />
A few people have put an 00str00der kit together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the extruder on the adapter plate.<br />
## Attach 00str00der+plate to an existing x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. The best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der tower<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
=== Version History ===<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
==== Version 0.9 ====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
==== Version 1.0 ====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
==== Version 1.1 ====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11424400str00der2014-01-01T21:52:44Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Assembly instructions===<br />
A few people have put an 00str00der kit together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the extruder on the adapter plate.<br />
## Attach 00str00der+plate to an existing x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. The best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der tower<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
=== Version History ===<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
==== Version 0.9: ====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
==== Version 1.0 ====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
==== Version 1.1 ====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11424300str00der2014-01-01T21:48:58Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the extruder on the adapter plate.<br />
## Attach 00str00der+plate to an existing x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. The best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der tower<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
==Extruder Calibration==<br />
===Configurator===<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
===Manual Procedure===<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11424200str00der2014-01-01T21:48:06Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed and knurled bolts with this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around revising this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the extruder on the adapter plate.<br />
## Attach 00str00der+plate to an existing x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. The best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der tower<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Extruder Calibration===<br />
====Configurator====<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
====Manual Procedure====<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11424100str00der2014-01-01T21:45:31Z<p>Free: /* Direct-Drive Configuration */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed bolts for testing on this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around modifying this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on many popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the extruder on the adapter plate.<br />
## Attach 00str00der+plate to an existing x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. The best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der tower<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
===Extruder Calibration===<br />
====Configurator====<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
====Manual Procedure====<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11424000str00der2014-01-01T21:44:49Z<p>Free: /* Direct-Drive Configuration */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed bolts for testing on this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around modifying this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. The plate is designed to work with hole spacing used on most popular open-source x-carriages found on the interwebs. (TODO: cite hole-spacing spec).<br />
## Assemble the extruder on the adapter plate.<br />
## Attach 00str00der+plate to an existing x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with many Mendel-type machines that use 50mm linear rail spacing. The best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
## Assemble the x-carriage<br />
## Assemble the 00str00der tower<br />
## Attach the 00str00der to the x-carriage<br />
## Replace an existing x-carriage with the new one.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
===Extruder Calibration===<br />
====Configurator====<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
====Manual Procedure====<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11423900str00der2014-01-01T21:35:07Z<p>Free: /* Direct-Drive Configuration */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed bolts for testing on this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around modifying this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. Pre-assemble the extruder on the adapter plate; then attach the assembly to an existing x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is designed specifically for the 00str00der and is compatible with most Mendel-type machines. The best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. Pre-assemble the x-carriage; then pre-assemble the 00str00der tower; then attach the two; and finally replace an existing x-carriage with the new one. CAD files for the Sheliak X-carriage are in the [http://terawatt-industries.github.io/prismx-scad/ PrismX 3D Printer Github repository].<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
===Extruder Calibration===<br />
====Configurator====<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
====Manual Procedure====<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11423800str00der2014-01-01T21:30:30Z<p>Free: /* Direct-Drive Configuration */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed bolts for testing on this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around modifying this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. Pre-assemble the extruder on the adapter plate; then attach the assembly to an existing x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is compatible with most Mendel-type machines and is also designed specifically for the 00str00der. The best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. Pre-assemble the x-carriage; then pre-assemble the 00str00der tower; then attach the two; and finally replace an existing x-carriage.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
===Extruder Calibration===<br />
====Configurator====<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
====Manual Procedure====<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11423700str00der2014-01-01T21:27:05Z<p>Free: </p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed bolts for testing on this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around modifying this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
=== Upgrade/Retrofit ===<br />
==== Direct-Drive Configuration ====<br />
Direct-drive configuration is where the 00str00der sits on a moving platform attached to the print-head (hot end), such as an X-carriage, as is popular on many Mendel-type designs.<br />
<br />
There are two ways to upgrade or retro-fit an existing direct-drive machine to an 00str00der:<br />
# Use the 00str00der Adapter Plate to attach to a compatible X-carriage. This is the fastest way. Pre-assemble the extruder on the adapter plate; then attach the assembly to an existing x-carriage.<br />
# Use the Sheliak X-Carriage to replace the entire x-carriage. The Sheliak X-Carriage is compatible with most Mendel-type machines. The best reason to replace the whole X-carriage is to take advantage of the press-fit bearing mounts on the Sheliak X-carriage. Pre-assemble the x-carriage; then pre-assemble the 00str00der tower; then attach the two; and finally replace an existing x-carriage.<br />
<br />
==== Bowden Configuration ====<br />
Bowden configuration is where the 00str00der sits stationary, attached to a printer frame or externally, such as on many Delta 3D Printers and the UConduit H-Bot 3D printer.<br />
<br />
For Bowden configurations upgrading or retrofitting an existing 3D printer with an 00str00der extruder should be straightforward. You will need to mount the 00str00der to the frame. The UConduit H-bot 3D printer has an example mount, but this is to attach to 3/4" tubing. Somebody needs to design a mount for other types of frame materials...<br />
<br />
===Extruder Calibration===<br />
====Configurator====<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
====Manual Procedure====<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11344400str00der2013-12-22T18:56:50Z<p>Free: /* Configurator */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed bolts for testing on this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around modifying this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Extruder Calibration===<br />
====Configurator====<br />
Terawatt Industries has created the [http://store.terawattindustries.com/00config 00str00der Configurator] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
====Manual Procedure====<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11344300str00der2013-12-22T18:56:32Z<p>Free: /* Configurator */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed bolts for testing on this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around modifying this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Extruder Calibration===<br />
====Configurator====<br />
Terawatt Industries has created the [00str00der Configurator http://store.terawattindustries.com/00config] which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
====Manual Procedure====<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Freehttps://reprap.org/mediawiki/index.php?title=00str00der&diff=11344200str00der2013-12-22T18:56:00Z<p>Free: /* Extruder Calibration */</p>
<hr />
<div>{{Development<br />
<!--Header--><br />
|name = 00str00der<br />
|status = working<br />
<!--Image--><br />
|image = 00str00der_firstever_1.JPG<br />
<!--General--><br />
|description = The RepRap Wiki 00str00der page.<br />
|license = GPLv3<br />
|author = Free<br />
|reprap = Wade%27s_Geared_Extruder<br />
|categories = {{tag|extruders}} {{tag|Cold End}}<br />
|cadModel = <br />
|url = <br />
}}<br />
<br />
The 00str00der is a belt-driven, gear-based, open-source extruder design intended for RepRap 3D Printers. It uses a precision linear-drive system to drive a hobbed bolt (or similar drive that grips filament/material), which in turn supplies filament to a nozzle used for 3D printing. The inspiration and research for this work was a natural progression based on existing open-source designs and is a result of collaboration between Lee Miller and Terawatt Industries (Colorado, USA). It is based on previous geared-extruder designs such as Wade's Geared Extruder, Adrian's Geared Extruder, and others; as well as Terawatt Industries' experience with RepRap drive systems.<br />
<br />
__TOC__<br />
<videoflash>_vMh1Gb-snw</videoflash><br />
==Summary==<br />
The designers first shared concepts for the component in 2012, and agreed to collaborate on design and testing in January, 2013. Lee Miller designed the first 00str00der for an H-Bot-style 3D Printer (TBA) with Bowden-style extrusion. Free Beachler of Terawatt Industries revised the design to work with a [[Prismx|PrismX]] by supplying the Sheliak X-Carriage design. Both designs are being converged (rev. C) and a mounting plate has been added to attach this extruder to carriages like [[http://www.thingiverse.com/thing:18657 http://www.thingiverse.com/thing:18657]]. <br />
<br />
==Background==<br />
The 00str00der is designed to be affordable while offering greater precision, durability, and speed compared to extruder designs based on printed gears. It uses a small closed-loop GT2 belt to transfer power from a NEMA17 motor to a M8 hobbed bolt. GT2 pulleys are used on the NEMA motor and hobbed bolt to achieve an approximately 4:1 gear ratio. PLA and ABS filaments are driven by an M8 hobbed bolt, as is 'traditional' in the related designs mentioned here.<br />
<br />
Terawatt Industries has tested and calibrated this component on a [[Prismx|PrismX]] running at infill speeds up to 400mm/s. The 00str00der was first tested and proven on a PrismX 3D Printer in March, 2013 by Terawatt Industries. In April 2013 tests with the 00str00der on an h-bot in Bowden configuration were performed by Lee Miller. It performs exceptionally well in both configurations. On the PrismX it printed approx. 250+ hours total in March-April 2013. <br />
<br />
I'll say qualitatively: it's difficult to drive a reprap (Prism, MendelMax, whatever) fast or hard enough to stress the 00str00der's drive system noticeably. During prints the nozzle experienced problems before we could drive our machine fast enough to stress the 00str00der or frame. During simple extrusion tests we hit speeds in excess of 1500mm/s; as noted before the nozzle shows problems performing at this speed.<br />
<br />
The primary advantages to this design approach include:<br />
* The belt-driven system is very smooth, therefore resistance in the drive system is decreased. The positive side-effects from this are several including: faster drive, more accurate drive, potential for smaller/cheaper/lighter motors such as NEMA14.<br />
* The belt-driven system can be precisely calibrated. Instead of marking filament and attempting to measure travel inside of the robot's gantry (frame), we can measure the width of the hobbed bolt, and use a calculator for the rest.<br />
* The belt-driven gear system is very durable. Printed gears shed PLA/ABS material within 100 hours of printing. The belts and pulleys are rated for 1000s of kilometers and more.<br />
* Set-screws on the GT2 pulleys work more effectively than most set-screws on printed gears. Last longer too.<br />
* The ratio of gears can be adjusted. One-to-one (direct-drive) can be achieved with a set of 36T GT2 pulleys.<br />
<br />
Some disadvantages to this system include:<br />
* The gears can't be printed, they must be sourced. This means we can't hack a new kind of herringbone gear and print/test it on an extruder. Purists will note, however, we can print decent GT2 pulleys in certain contexts...<br />
* All the other disadvantages that come with using non-printed parts such as: finding suppliers, specifications, availability, lead-time, etc.<br />
<br />
==Mechanical Construction==<br />
=== Materials ===<br />
'''NOTE:''' Refer to the "Version History" section for information about the 00str00der's change history. These photos and BOM lists are not always current. However, the variations in the 1.x versions are slight and photos from older versions should still assist in assembly.<br />
<br />
Version 1.0 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v10<br />
<br />
Version 1.1 BOM:<br />
http://kitbom.com/terawattindustries/00str00der-extruder-v11<br />
<br />
==== Printed Parts ====<br />
See Terawatt's 00str00der Github repo for slicing instructions.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" class="unsortable" | Comments<br />
! scope="col" class="unsortable" | Diagram<br />
|-<br />
| 1 || extruder block || || [[File:00str00_reva_snapshot00.jpg|200px|thumb|center|00str00der block]]<br />
|-<br />
| 1 || extruder idler block || || [[File:00str00_reva_snapshot01.jpg|200px|thumb|center|00str00der idler block]]<br />
|-<br />
| 1 || adapter plate || '''optional''' - for mounting to www.thingiverse.com/thing:18657 - not needed for Sheliak X-Carriage || [[File:00str00_revc_snapshot02.jpg|200px|thumb|center|mount adapter plate]]<br />
|}<br />
<br />
==== Non-Printed Parts ====<br />
'''NOTE:'''<br />
* hardware BOM has changed in version 1.0; refer to "Version History" section.<br />
* pulley sizes have changed in version 1.1; refer to "Version History" section.<br />
<br />
{| class="wikitable sortable" border="1"<br />
|-<br />
! scope="col" | Quantity<br />
! scope="col" | Description<br />
! scope="col" | Type<br />
! scope="col" class="unsortable" | Comments<br />
|-<br />
|colspan="4"|'''Drive System'''<br />
|-<br />
|colspan="4"|[[File:00str00der-13.jpg]]<br />
|-<br />
| 1 || 65T Plastic GT2 Pulley, 8mm bore, 2mm pitch, 6mm width || Drive System || '''8mm bore''' for hobbed bolt; metal pulleys are OK; ''note: if this pulley does not have a set screw you will need an M8 nylock nut for the hobbed bolt''<br />
|-<br />
| 1 || 17T Plastic GT2 Pulley, 5mm bore, 2mm pitch, 6mm width || Drive System || '''5mm bore''' for NEMA motor; metal pulleys also work; ''must have set screw''<br />
|-<br />
| 1 || GT2 Belt, 88T, 186mm length, 2mm pitch, 6mm width || Drive System || +/- 1 tooth works OK<br />
|-<br />
|colspan="4"|'''Feeder'''<br />
|-<br />
|colspan="4"|[[File:00str00der-22.jpg]]<br />
|-<br />
| 3 || 608 bearings, skateboard bearings || Bearings ||<br />
|-<br />
| 1 || M8×60mm hobbed bolt (65mm works better perhaps) || hobbed bolt || M8×60 doesn't make it through the pulley completely, 65mm is perhaps better<br />
|-<br />
| 1 || <strike>M8 Fender Washer</strike> || <strike>Fastener</strike> || originally used since fender washers are slightly thicker than standard, optional<br />
|-<br />
| 4-5 || M8 washers || Fastener || to space the large pulley clear of the extruder base<br />
|-<br />
| 1 || M8 nylock nut || Fastener || '''optional''' - not pictured - I recommend using the set-screw on the M8 GT2 pulley to tighten things<br />
|-<br />
|colspan="4"|'''Idler'''<br />
|-<br />
|colspan="4"|[[File:00str00der-19.jpg]]<br />
|-<br />
| 1 || 608 bearing, skateboard bearing || Bearings || the 608RS are resealable, so if they get clogged with plastic the bearing cage can be cleaned, and re-assembled.<br />
|-<br />
| 1 || M8×20 || Threaded rod ||<br />
|-<br />
| 1 || M3×30 button-head cap screw || Fastener || mount idler arm to extruder block<br />
|-<br />
| 2 || M4×50 socket-head cap screws || Fastener || for idler tension<br />
|-<br />
| 3 || M3 nuts || Fastener || one (1) for button-head screw<br />
|-<br />
| 5 || M3 Fender washers || Fastener || one (1) for button-head screw - std washer is OK<br />
|-<br />
| 2 || ~4mm ID springs || Spring || Sized to fit over an M3/M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.<br />
|-<br />
|colspan="4"|NOTE: Some users have their extruders working without springs, but springs are recommended. Even better than springs are rubber gaskets. It can be tough to find good springs - often a local hardware store has an assortment and something in there might work. Also check with the recommended vendors.<br />
|-<br />
|colspan="4"|'''Hotend Mount''<br />
|-<br />
| 2 || M3x30mm button-head cap, hex-head, or socket-cap screw || Fastener || NOTE: extruder block is revised for M3 screw<br />
|-<br />
| 2 || M3 nut || Fastener ||<br />
|-<br />
|colspan="4"|NOTE: The only current tested hotend mount is the j-head style mount reflected in the SCAD/STL files for the extruder block.<br />
|-<br />
|colspan="4"|'''Stepper Motor Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der_-_14.jpg]]<br />
|-<br />
| 2 || M3×12 bolts || Fastener || M3x10mm is OK without lock washers<br />
|-<br />
| 2 || M3 Fender washers || Fastener || std. washers will work<br />
|-<br />
| 2 || M3 lock washers || Fastener || optional - resists vibration<br />
|-<br />
|colspan="4"|'''Stepper Motor'''<br />
|-<br />
| 1 || NEMA 17 bipolar stepper motors || Stepper || 0.49 Nm (69 ozf*in) works well. We've been using the Stepper Motors from Terawatt Industries and it appears to be more force than necessary. Should be capable of creating a holding torque of at least 0.4Nm (56.6 ozf*in), at the very least.<br />
|-<br />
|colspan="4"|'''Extruder Mount'''<br />
|-<br />
|colspan="4"|[[File:00str00der-11.jpg]]<br />
|-<br />
| 2 || M4×20 socket cap screw || Fastener || The Sheliak X-Carriage has a three-point mounting system for this extruder.<br />
|-<br />
| 1 || M4×20 button head cap screw || Fastener || Required. We're discussing a revision so a regular screw can be used.<br />
|-<br />
| 3 || M4 nuts || Fastener || x-carriage mount - nylock nuts are better, then skip the lock washers<br />
|-<br />
| 3 || M4 washers || Fastener || x-carriage mount<br />
|-<br />
| 3 || M4 lock washers || Fastener || optional if using nylock nuts<br />
|}<br />
<br />
===Assembly instructions===<br />
We still need assembly instructions for the latest version. However many people have put their 00str00der kits together with only assembly guides based on earlier ancestors:<br />
* [[http://mendelmax.terawattindustries.com/extruder/index.html http://mendelmax.terawattindustries.com/extruder/index.html]]<br />
* [[http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions http://garyhodgson.com/reprap/wades-geared-extruder-visual-instructions]]<br />
<br />
===How to make the hobbed bolt===<br />
We've been using Terawatt Industries hobbed bolts for testing on this component, which is a M8x60mm bolt hobbed at 30mm from the head. 65mm+ works slightly better with the current (Rev. B) extruder block design. We're considering a few options around modifying this, including using a non-threaded M8 rod or other machined options; but currently the 'traditional' hobbed bolt works great.<br />
<br />
If you don't want to purchase a hobbed bolt then [[Wade%27s_Geared_Extruder]] describes how to make your own.<br />
<br />
==== Version History ====<br />
'''NOTE:''' ''The photos above apply to version 0.9''.<br />
<br />
===== Version 0.9: =====<br />
* Rev. A: for use with h-bot in Bowden configuration<br />
* Rev. B: for use with Prism/MendelMax machine; 3-point attachment to Sheliak x-carriage<br />
* Rev. C: converges rev.A + B; testing started: for use with M4x50mm bolts on idler<br />
<br />
===== Version 1.0 =====<br />
Based on 0.9 Rev. C. Considered stable. Vitamin BOM refined for nylock nuts and M4 screws for j-head groove-mount.<br />
<br />
The complete version 1.0 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v10 http://kitbom.com/terawattindustries/00str00der-extruder-v10].<br />
<br />
===== Version 1.1 =====<br />
Considered stable. Same as version 1.0 but with 60T big pulley, 16T small pulley. 16T pulleys easier to source; 1:3.25 ratio reduces torque on tower; 60T pulley allows access to groove mount set-screws.<br />
<br />
The complete version 1.1 BOM can be found on KitBom at [http://kitbom.com/terawattindustries/00str00der-extruder-v11 http://kitbom.com/terawattindustries/00str00der-extruder-v11].<br />
<br />
===3D CAD Files===<br />
STL and OpenSCAD source files for the latest version can be found on Github at [https://github.com/Terawatt-Industries/00str00der https://github.com/Terawatt-Industries/00str00der] and [https://github.com/iquizzle/00str00der https://github.com/iquizzle/00str00der].<br />
<br />
IMPORTANT: STL files are not organized by version number - they are organized by GT2 pulley and belt sizes. Read the README file at https://github.com/Terawatt-Industries/00str00der/dist/stl/README.md for more.<br />
<br />
===Extruder Calibration===<br />
====Configurator====<br />
Terawatt Industries has created the 00str00der Configurator which calculates the steps-per-mm for you. To use the 00str00der Configurator open a web browser to [http://store.terawattindustries.com/00config http://store.terawattindustries.com/00config].<br />
<br />
====Manual Procedure====<br />
The procedure to calibrate the 00str00der is as follows:<br />
* Measure the O.D. of the knurled (hobbed) area of the M8 hobbed bolt, preferably with digital calipers. The exact OD will depend on things like manufacturer and batch.<br />
* Calculate the gear ratio between small and larger gear.<br />
* Find the step angle for the motor - most common NEMA17 motors are 200 steps per revolution.<br />
* Find the microstepping value supported by your stepper drivers. This usually depends on brand of driver and type of control electronics.<br />
* Use the following formula:<br />
<br />
steps_per_mm = (gear_ratio / (hobbed_bolt_OD * Pi)) * ((360 / motor_step_size) * (1 / driver_microstepping))<br />
<br />
For example:<br />
* A hobbed bolt where the knurled bolt measures 7.52mm in outer-diameter (O.D.)<br />
* The gear ratio for a 17-to-65-tooth gear system is ~3.8235. In other words, ~3.8235 revolutions of the smaller gear equal one revolution of the larger gear. <br />
* NEMA17 motors are common with 1.8 step angle and RAMPS 1.4 with pololu drivers supports 1/16 microstepping.<br />
<br />
steps_per_mm = (3.8235 / (7.52 * 3.1416)) * ((360 / 1.8) * (1 / 1/16)) = 517.8957 ~= 517.9<br />
<br />
==Stepper Driver==<br />
<br />
You can use [[Official_Electronics#RAMPS|community-tested electronics]] to drive this extruder. Newer electronics like Smoothieboard will work fine too.</div>Free