User:KRtekTM/Kossel-XL

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Kossel-XL

Release status: working

KosselMinivsXL.jpg
Description Delta robot 3D printer with extrusion frame.
License GPL
Author KRtekTM
Contributors
Based-on Rostock
Categories Kossel
CAD Models github.com/jcrocholl/kossel
External Link none


Kossel-XL is a parametric delta robot 3D printer, based on Kossel printer (by Johann).


Design Goals

  • Kossel-XL is commercial printer shipped as upgradeable kit for Kossel Mini printer.
  • This page discribes bill of material used for build Kossel-XL printer from scratch.
  • With Kossel-XL, You're able to print bigger objects than on standard Kossel thanks to the bigger round glass.

Bill of Materials

Printed parts

This set of parts weighed in at 271g (without power supply brackets).

All files come from Johann's Kossel repo: github.com/jcrocholl/kossel

Recommended print settings:

  • Layer height = 0.2 to 0.3 mm (around 60% of your nozzle size)
  • Perimeters = 3
  • Top/bottom solid layers = 3
  • Infill density = 50%

Frame

  • 3x 750mm Black OpenBeams
  • 9x 360mm Black OpenBeams
  • 1x 250mm Round Borosilicate Glass Plate
  • 1x 220mm Round Heated Bed

Fasteners

  • 100x M3x8mm stainless steel screws (frame and most connections)
  • 100x M3 stainless steel nuts
  • 100x M3 nyloc nuts
  • 6x M3x20mm stainless steel screws (arm attachment to vertical carriage)
  • 12x M3x25mm stainless steel screws (belt idlers and effector-rod attachments)
  • 6x M3x35mm stainless steel screws (tensioners)
  • 50x M3x6mm stainless steel screws (rail attachment to extrusions - 8mm is too long!)
  • 12x M3x16mm stainless steel screws (push rod attachment)
  • 6x M2.5x12mm screws (micro switches)
  • 3x M2.5x16mm (automatic bed leveling probe)

Linear motion

  • 3x 400mm hardened steel rail and carriages HIWIN MGN-12H
  • 3x 1164mm GT2 belt closed loop with 2mm pitch and 6mm width
  • 1x GT2 Belt (5m)
  • 6x F623ZZ flanged bearings 3x10x4mm (or F684ZZ 4x9x4mm for printed parts before June 21st)
  • 3x GT2 pulley with 16 teeth and 2mm pitch
  • 3x Kysan NEMA17 stepper motor

Diagonal push rods

  • 12x Traxxas 5347 rod ends
  • 12x M4x20mm set screws
  • 12x Hollow Ball Joints
  • 15x M4x20 Hex bolts
  • 6x Carbon Rod (300mm)

Bowden

  • 1x J-Head Hotend 0.5mm for 1.75mm filament
  • 1x Clear PFA tubing ID=2mm OD=4mm
  • 2x Push fit connector ID=4mm with M5 thread.

Motor

  • 1x NEMA-17 motor with an integrated Planetary gearbox with a 5 2/11 :1 ratio..
  • 1x Spur Gear, 22 Tooth, 12mm od, 8mm id. Alternately, a Hardened MK7 drive gear that fits the geared stepper motor.
  • 3x M3-0.5x25 Cap Screw
  • 3x M3 Washer

Idler

  • 1x 625 ball bearing (5x16x5)
  • 1x M5-0.8x20 Cap Screw
  • 1x M5 Washer
  • 1x M5-0.8 Hex Nut (Nylock optional)
  • 1x M3-0.5x16 Cap Screw
  • 1x M3 Washer
  • 1x M3-0.5 Hex Nut, Nylock

Endstops

  • 3x 36K7635 Omron SS-5 micro switch or 52672 Honeywell ZM10B10A01

Automatic Bed Leveling Options - Only need one of the following, depending on which you choose.

 FSR(force sensitive resistor)
  • 3x FSR circular pads
  • 3x mounts for fsr pads
  Bed leveling probe
Z-probe showing safety pin detail.
  • 1x Micro switch (same as for endstops above)
  • 1x Bondhus 1.5mm allen wrench
  • 1x Safety pin with 2.5mm loop
  • 2x Ball point pen spring
  • 1x Euro-style terminal block connector
  • 1x Heat shrink tubing ID=2mm
 Proximity Sensor

Excellent guide to set up proximity leveling can be found on Instructables, search for "auto bed leveling Marlin"

  • 1x PNP Inductive proximity sensor

Several versions are available but the most popular and simple to use is the LJ12A3-4-Z/BY. This model works at 6-36vdc(many other models need at least 12v), and has a sensing distance of 4mm. Can be bought on eBay for <$5

  • 1x mount for your specific effector/carriage

Electronics

Tools

This is not a comprehensive list, but should give you an idea of what tools may be required. Review all build manuals/videos to ensure you have all necessary tools.

  • 1x metric caliper
  • 1x M4 Tap Drill bit
  • 1x M5 Tap Drill bit
  • 1x 1.5 mm allen wrench
  • 1x slow-set epoxy

Assembly instructions

Follow Kossel wiki for tutorial.

Downloadable content

  • Firmware: download.krtkovo.eu/kosselxl/firmware/Kossel-XL.zip