cOssel is an iteration of Johann's Kossel. Design intents are equip a dual head end effector and to move the linear rails to an open design. It also uses 20x20 instead of 15x15. All other tweaks are minor. This design otherwise entirely copies Johann's delta-bot intent. Default configuration is setup for dual extruders, heated bed, and EE fan. The O in cOssel is intended to be significant as a commitment to using open designs, when applicable & feasible.
cOssel attempts to enable a low-power, non-contact autoleveling sensor as an alternative to using a retractable mechanical switch as used in other Rostock/Kossel deltas. This feature is still experimental as most IR sensors have not been proven repeatable, thus is still unfit for use. Video: Infrared Leveling
The assembly process should take a short weekend to complete. Make sure that you have a standard tool set, including ball-end metric allen keys.
- Be mindful that once the aluminum extrusions are installed, in many places you are unable to insert extra extrusion nuts after the fact. It may be worthwhile to insert extra nuts for extendability on various 2020 members active slots.
- Warning: The images below do not always show the best build sequence. Read the text, which has been revised since all of the images have been taken for the easiest build sequence!
- Please, ask questions in the discussion page for help! Talk:cOssel
Main Vertical (Post) Assembly
- Cossel ee top.JPG
- Cossel probe 1.JPG
- Cossel probe2.JPG
The following images show the terminal block on the board. I ended up removing the terminal blocks from the boards to reduce interference from the carriage assembly as it approached the Z_MAX home position.
- Cossel estops 3.JPG
End stops 3
It is assumed that your push rods have already been cut to size by yourself or a vendor. If not, cut your rods to length.
- Place the rod end ball standing vertically on a stable surface.
- Place the rod end socket loosely over the ball end ball.
- Space a pair of needle nose pliers around the perimeter of the socket.
- Press firmly down and click the socket over the ball.
- Prepare the epoxy solution.
- Apply dab of mixed epoxy onto threaded 4mm dia, 20mm long set screw
- Thread set screw into rod end as deep as it will go
- Apply another dab of epoxy onto the set screws, this time, more generous
- Gently place the set screws into the carbon fiber tube.
- Firmly press both opposing rod ends together along the tube axis.
- Set rod to try. Ensure that rod ends are parallel with each other.
Frame - External
The RAMPS_1.4 board does not by default have sufficient IO to power three heaters and additional fans for the extruder heaters. Products exist already to serve this need, but I decided to build my own. I added a constant 12V drop for a always-on stepper driver cooling fan (so long as PS-ON is on), and a PWM circuit for a single extruder cooling fan. I shall use only one fan for both extruders. The #BOM includes links to purchase an off-the-shelf board for this purpose.
The BOM for COssel is large, thus has been collapsed to not overflow the page. Expand the table below for a flat Bill of Material for procurement! The BOM is also formally maintained here in Microsoft Excel format (.xlsm): cOssel BOM. Please note:
- Electrical connectors are not covered in the BOM. It is assumed that the user has some experience with basic wiring.
- A supply of 22 AWG (+/- 2 AWG) is also good to have on hand. Even, better, some ribbon cable will do good things!
- Thermistors are not covered in the BOM. You will need to procure these on your own, as you need. I often equip the EPCOS 100K thermistor on my machines for the heated bed.
|Part||Total Qty||Vendor||MFG PN||Vendor PN||Notes||Link|
|2020_cap||16||Misumi||HFC5-2020||HFC5-2020||Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order.|||
|2020-134mm||1||Misumi||HFS5-2020-134||HFS5-2020-134||Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order.|||
|2020-200mm||3||Misumi||HFS5-2020-200||HFS5-2020-200||Site is designed for commerical customers, but you can still setup an account. You must manually enter the part numbers into a purchase order.|||
|bed_glass||1||SeeMeCNC||26602||300mm, round borosilicate!|||
|belt_gt2_1700mm||3||OpenBuilds||Order by the foot. 304.8 mm / ft!|||
|brace_frame||6||Ponoko||Legacy brace. Still may be viable and desired by some users. Included by default in Ponoko cut-out .svg|||
|brace_spacer||12||Ponoko||Legacy brace. Still may be viable and desired by some users. Included by default in Ponoko cut-out .svg|||
|bracket_heater_sppt_wood||1||Ponoko||Wooden piece. Laser cutting files on GitHub & ponoko|||
|bracket_hot_end_groovemount_dual||1||Ponoko||Wooden piece. Laser cutting files on GitHub & ponoko|||
|bracket_power_supply_stablity_xy||1||Ponoko||Wooden piece. Laser cutting files on GitHub & ponoko|||
|cable_ribbon_10_conductor_15ft||2||SparkFun||CAB-1064||Used for bulk-running the opto +V, SIG, & GND to the board. Also used for clean motor runs and I/O to the EE. Note, some have suggested this is too thin of wire gauge. User to decide|||
|drive_filament_dia||2||RepRap Sources||Mk7-like with 8mm bore to be compatible with phidgets geared steppers.|||
|epoxy_two_part||1||Amazon||For gluing the rod ends to the carbon tubing|||
|extruder_maker_gear||2||MakerGear||Make sure to configure your order for 1.75 barrel.|||
|fan_40mm_12VDC||2||Amazon||Most 40mm 12VDC fans should do the trick|||
|fitting_one_touch_4mm||4||Amazon||KQ2S04-M5A||5mm thread req'd and 4mm OD tube receptable req'd|||
|gear_drive_belt_gt2||3||OpenBuilds||20 tooth or less is critical to prevent the belt from hitting the carriage|||
|motor_nema_17||3||Ultimachine||UMN17MTR||Std reprap motor|||
|motor_nema_17_geared_5.18_1||2||Phidgets||3317_1||Extra torque required for long bowden path to hot end|||
|nut_extr_m5 (open_rail_kit_excess)||69||OpenBuilds||Do not order directly for hardware. You will have excess from your wheel kits which instead use the eccentric spacer.|
|nut_m3||35||Fastenal||Nylon lock preferred|||
|nut_m4||20||Fastenal||Nylon lock preferred|||
|open_rail_bearing||24||OpenBuilds||Do not order directly for hardware. You will have excess from your wheel kits which instead use the eccentric spacer.|
|open_rail_nut_m5||14||OpenBuilds||Do not order directly for hardware. You will have excess from your wheel kits which instead use the eccentric spacer.|
|open_rail_shim_eccentric||6||OpenBuilds||Stock availability can be shaky. May need to adapt a different eccentric nut.|||
|open_rail-700mm||3||OpenBuilds||Order the 1000mm's and cut to length|||
|pcb_arduino_mega||1||Ultimachine||Note: The RAMPS stack below includes a MEGA 2560. Make sure not to double buy!|||
|pcb_fan_extension_board||1||Geeetech||Or make your own! cdaringe opto-extension board|||
|pcb_RAMPS_stack||1||Ultimachine||Single Z, not dual Z configuration.|||
|pcb_sd_ramps_extension_board||1||Geeetech||Strongly recommended as pausing issues occur when printing via USB|||
|power_supply||1||Thermaltake||TR2 TR-700||N82E16817153167||ATX PS. Quiet, reliable.|||
|rod_carbon_330mm||6||Hobby-Lobby||GXT5540||Must be cut to size. 3x 1000 rods will satisfy a std build|||
|rod_ends||12||Amazon||5347||4mm OD receptable, 3mm thru-hole ball-ends|||
|rod_threaded_8mm-271mm||1||Grainger||5/16" rod is ~8mm too. You can buy 5/16" rod at hardware stores (i.e. Home Depot) for a couple of bucks.|||
|rp_base_vertex||3||RP||RP||RP||Files on GitHub|||
|rp_block_bed||3||RP||RP||RP||Files on GitHub|||
|rp_brace_top_vertex||3||RP||RP||RP||Files on GitHub|||
|rp_bracket_axle_spool||3||RP||RP||RP||Files on GitHub|||
|rp_bracket_lateral_sppt||4||RP||RP||RP||Files on GitHub|||
|rp_bracket_lateral_sppt_mirrored||4||RP||RP||RP||Files on GitHub|||
|rp_bracket_pwr_spply_tab||2||RP||RP||RP||Files on GitHub|||
|rp_bracket_RAMPS||1||RP||RP||RP||Files on GitHub|||
|rp_end_effector||1||RP||RP||RP||Files on GitHub|||
|rp_extruder_cossel_bowden_mirrored||2||RP||RP||RP||Files on GitHub|||
|rp_extruder_join_lower||1||RP||RP||RP||Files on GitHub|||
|rp_extruder_join_upper||1||RP||RP||RP||Files on GitHub|||
|rp_flag_carriage||3||RP||RP||RP||Files on GitHub|||
|rp_idler||1||RP||RP||RP||Files on GitHub|||
|rp_idler_boss_bearing_8mm||2||RP||RP||RP||Files on GitHub|||
|rp_idler_mirrored||1||RP||RP||RP||Files on GitHub|||
|rp_idler_strut||2||RP||RP||RP||Files on GitHub|||
|rp_mount_fan_ee||1||RP||RP||RP||Files on GitHub|||
|rp_mount_fan_motor_drivers||1||RP||RP||RP||Files on GitHub|||
|rp_opto_mount||3||RP||RP||RP||Files on GitHub|||
|rp_plate_slider||3||RP||RP||RP||Files on GitHub|||
|rp_upper_vertex||3||RP||RP||RP||Files on GitHub|||
|scrw_finish_#6||1||Fastenal||Thermal switch is not required, but strongly recommended for safety|
|scrw_m3_10||8||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m3_12||18||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m3_15||14||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m3_20||17||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m3_25||2||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m3_35||2||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m3_50||4||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m3_set||5||Fastenal||Only order this if your timing pulleys and filament drive gear do not come with their own. They nearly always do.|
|scrw_m4_10||47||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m4_12||30||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m4_15||25||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m4_20||12||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m4_25||4||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m4_8||22||Fastenal||Pan head & SST preferred when applicable.|
|scrw_m4_set_20||12||Fastenal||Rod End Mounts|||
|scrw_m5_10 (open_rail_kit_excess)||67||OpenBuilds||Do not order directly for hardware. Hardware comes kitted with your rail.|||
|spring_m3_extruder||4||Home Depot||Only 1x spring kit reqd|||
|spring_m4||7||Home Depot||Only 1x spring kit reqd|||
|switch_thermal||1||Amazon||Amico KSD301||Recommended for safety|||
|tab_felt||3||(no vendor data entered)||This is a thermal barrier between the bed and the bed clamp. Simply household cloth shall suffice.|
|tubing_4mm_bowden_1000mm||2||MakerShop||Any common RepRap 4mm tube shall suffice|||
|wire_raceway_10in||1||McMaster-Carr||7578K73||The 6'6" is enough for your full build|||
|wire_raceway_25in||1||McMaster-Carr||7578K73||The 6'6" is enough for your full build|||
|wire_raceway_5in||2||McMaster-Carr||7578K73||The 6'6" is enough for your full build|||
|wire_raceway_8in||1||McMaster-Carr||7578K73||The 6'6" is enough for your full build|||
|wire_wrap_10ft||1||McMaster-Carr||7378K41||Pick a color! You may use 8+ ft.|||