About this project
The DeltaTrix 3D Printer is a serious Additive Manufacturing tool, based on a linear delta robot platform. It is a departure from previous generations of 3D delta printers, which were based on linear rods or aluminium extrusions. Rods are liable to flex and aluminium extrusions make any machine look like it belongs in a factory. Robust and well designed, the DeltaTrix 3D Printer delivers a new level of sophistication and quality.
We do not believe in short cuts when it comes to our designs. Being experienced in machine design, we know there is no substitute for quality components and sound engineering practice. On our machine there are no "DIY" bearings with unknown life expectancy, but proper items which have been developed and manufactured for their purpose. Although a cheaper option might seem to make sense in the short term, it often ends up being a more expensive option in the long run!
About the DeltaTrix 3D Printer
The design of the DeltaTrix 3D Printer is published on Instructables as an Open Source project. The currently published version should provide sufficient information to recreate one of our prototype machines. If you are eager to get your hands on a printer and you have the right skills/ tools, head over to Instructables now and get busy! Alternatively, choose a kit or panel set from one of the Rewards in this Kickstarter and assemble the production version of our printer. Not confident assembling a kit? After shipping all of the Kickstarter rewards, we are aiming to provide kits and complete machines from our webstore (currently under construction, to go live after fulfilling the Kickstarter pledges).
The theoretical printing area is 275mm in diameter. As a square this works out as (almost) 200x200mm (8"x8"), which suits a generic 'MK2A' heated bed. As it is also useful to be able to remove items, the gap between the uprights is just over 295mm. The maximum build height is over 250mm.
- Linear delta robot layout provides a mechanically simple motion platform for moving the print head only, not the workpiece. This allows for very fast printing speeds.
- Pre-assembled uprights in combination with a self-aligning frame design, allow for a very easy frame assembly.
- Off the shelf RUMBA electronics allow for easy replacement in case things go wrong.
- Using an LCD display and a 4GB SD memory card (supplied in our kits), the DeltaTrix 3D Printer can operate on it's own. It does not need to be attached to a computer.
- With our initial machines we achieved a step size of 12.5 micron, enabling a layer thickness of 100 micron. We have printed several items at 100 micron to prove this capability. For the production machine we will have a step size of 3.125 micron, enabling a theoretical 25 micron.
- There are several (Open Source) options in terms of software. At the moment we are using Repetier on the PC, a modified version of Marlin as the firmware on the electronics, and the standard Arduino IDE for tweaking the firmware.
- A heated bed with mirror glass print surface, allows for PLA and ABS to be used as filament. In terms of filament, the DeltaTrix 3D Printer is designed to accept 1.75mm PLA and ABS on a variety of 1kg reels, as long as it is of good quality. We have tested the cheapest possible materials, from a number of sources, to expose our machine to worst-case conditions.
- Igus linear slides with pretension are used, providing a robust and durable bearing solution from a highly reputable, German manufacturer. The strengthening ribs on the uprights keep the rails straight and sturdy.
- The current design print head assembly uses a single Reprappro Hot End, with a nozzle size of 0.3 or 0.5mm. The assembly also has a fan and integrated duct for cooling the top of a print. Quick changeover print head assembly. Useful for swapping between two print head assemblies, eg. one with a 0.3mm nozzle for high detail prints and one with a 0.5mm nozzle for faster prints. Please, note: the standard kit only contains parts for one off print head assembly.
As panel material for the prototypes we used (floorboard quality) plywood from our local DIY shop, which we machined on our own 3 axis CNC machine. For the Sets and Kits on offer as rewards, we will be providing panels from a well established UK timber merchant. Using their professional grade CNC machines, they will supply us with fully machined panels.
The panel material on our printer is Valchromat, resulting in a machine weighing around 15.5 kilograms. The Black Edition Sets and Kits will have panels in black Valchromat. We feel this choice of material will result in a very solid machine, with great aesthetic properties.
- Tracker Reward: This reward will allow you to keep track of our progress. As this is the only reward without physical shipment, it is also the most environmentally friendly contribution!
- Personalized Key Fob: The Key Fob is the ideal sample from our DeltaTrix 3D Printer. It features layer thickness of 100 micron, in conjunction with a high level of accuracy. 3D printing is all about customisation, and the Key Fob demonstrates this by having your own initials on one side.
- Plastic Parts Set: The Plastic parts Sets are usefull for makers having access to a CNC machine, but not being able to print the plastic parts themselves. Make the panels yourself on your own CNC and source all other components yourself.
- Panel Sets: The Panel Sets are great for tinkerers who would like to build a customized version of the DeltaTrix 3D Printer, but who do not have (affordable) access to a large CNC machine. You might already have all the electronics, or you prefer a particular model hot end, or maybe you want to design your own chocolate extruder...
- Reprap Upgrade Kits: The Reprap Upgrade Kits allow the build of a DeltaTrix 3D Printer, by re-using parts from an existing Reprap 3D printer or similar.
- Lucky 7 Kits: The Lucky 7 Kits are essentially the same as the Comprehensive Kits (see below), but at a lower price and in limited quantities.
- Comprehensive Kits: Available with panels in Black Valchromat, Comprehensive kits come with all the parts to assemble a DeltaTrix 3D Printer
- Comprehensive Kits + one day workshop: We will organize a few workshops to take place in Newport, South Wales (UK). During the first half of the day the focus will be on the physical assembly of your own printer. The rest of the day will be used to set your printer up, to install software on your own laptop/PC, and to go through the steps needed to make prints. The actual dates will be arranged after the Kickstarter campaign finishes, but will typically take place during the normal working week.
- NEW, NEW, NEW: Optional Door Panel Sets are now available for an additional £100! The set consists out of three clear, transparent door panels, which have been vacuum formed out of PETG for a perfect fit. Removable pin hinges, magnetic door catches, self adhesive sealing foam strip, door handles, and fasteners complete the set. Simply add £100 to your existing pledge in order to get the set!
If you are interested in a set or kit, be sure to check out the existing Instructable for the DeltaTrix 3D Printer. This will give you an idea about the work involved in assembling a kit. Please note, the initially published version corresponds to the two initial prototypes. The sets and kits on offer as rewards will have a small number of differences, which will be published in due course. The main differences are:
The LCD surround and reel holder are to be re-designed as plastic parts. On the currently published V0.1x design, these parts are in plywood. The top and bottom horizontal panels have already been re-designed to be identical to each other, in order to simplify the production process. The published design is based on T2.5 timing belts and pulleys. The production version will be based on GT2 belts and pulleys.
There are a few improvements and upgrades possible. Listed here are a few things we are planning to work on, and also some potential improvements users can perform on their own initiative. We would like to stress that there is no guarantee for any to become reality:
- Automatic levelling by means of an optical sensor and a mirror glass build surface. We already fitted and wired sensors to our prototype machines, but have not yet set up the software side of things. All comprehensive kits will include a sensor and a mirror glass build surface, so they will be ready for a future upgrade.
- The print head design includes an integrated fan duct, which works as intended. With the print head being a very important part of the machine, this is an area for potential improvements.
- Any improvements we will come up with, will be made available on the basis of Open Source principles. In case of improved 3D printed parts, these will be made available as downloadable files for printing on your own printer.
- There is the potential for installing a second extruder and a dual print head. We already designed a dual print head assembly, which includes a provision for cooling the top of a print. We still need to do some testing with it before releasing the design files. When we do, they will be avaliable on Instructables!
- With the DeltaTrix 3D Printer having three identical towers, it is actually possible to fit three extruders. We will be looking at designing a triple nozzle print head, but this is at a very early stage. For this we intend to use J-head nozzles and as soon as we have something that works, the design files will also be made available. Be aware, this may take some time...
- All of the sides have a defined opening, ready to accept a door panel for closing them off. As the print head can go beyond the door opening, any potential door panel would need to accommodate this. We are currently working on the tooling for producing clear, vacuum formed panels. Update to follow soon!
- On top of the printer there is space for something. A netbook will easily fit, or the filament reel could be placed on top in conjunction with moving the extruder. A very interesting (and ambitious!) prospect would be to use the space for including a 3D scanner...
Our printer is fully Open Source and any of our upgrades to it will also be Open Source. Feel free to upload your own improvements on Open Source principles, for the benefit of other users!
VAT, Duty and Shipping
In order to achieve the lowest possible price for end users, we will limit our offered rewards (total EU sales to be below £79000!) in order to prevent having to become VAT registered. As such, UK and EU customers will avoid having to pay the 20% Value Added Tax. Indirectly there is still some tax included, as we will not be able to get any VAT back for items we need to purchase ourselves.
Rewards to the USA, Canada, Mexico, and the Rest Of The World will be shipped on Incoterms DDU (Delivered Duty Unpaid). This means we will take care of delivering your reward to you, but you will be liable for paying potential duty and customs clearing expenses.
Shipping charges can very complicated. As an example, our shipping quotation from DHL divides up worldwide destinations in no less than ten regions! We have spent a lot of effort in defining upfront shipping charges for our rewards, which are easy enough to apply and at the same time are as fair as possible. Still, if you have any specific questions regarding this, please ask!
To be complete, here are the values we will declare to our courier for the different rewards:
For customs purposes, Key Fobs will be valued at £10 and marked as 'sample'. At this level, there should not be any import duty payable for international delivery. The fobs will be sent by Royal mail. The Panel sets and the kits will have the following declared values:
- Panel Set £125
- Reprap Upgrade Kit £335
- Lucky 7 Kit £540
- Comprehensive Kit £600
Note: after Kickstarter we are planning to offer further Comprehensive Kits at the price of at least £660 + VAT(where applicable).
The Peoples behind DeltaTrix
The way our project will take place will depend on the success of the Kickstarter campaign. In case of very low interest we would print all the necessary plastic components on our existing prototype machines. As soon as the campaign pledges increase, we would first need to assemble more printers in order to print all the parts for the Kit Rewards. At a very high pledge total we plan to have certain plastic components made for us in injection moulded form.
Without going into details too much, here are the key phases for our timeline:
- Start printing plastic parts for the manufacture of our own 3D printer battery, needed for printing kit parts in volume. Already started, to continue during the KS campaign.
- Our supplier for injection moulded parts is geared up for fast turn around, mid-volume (up to 10000 parts...) production. Once we supply them with our 3D models and place an order, they will have parts ready within 15 days.
- Receive funds from Kickstarter by the end of May/beginning of June. Upon receiving funds, we will first place orders for all items with a long lead time. These will primarily be all items we need to get from China: electronics (RUMBA, End stops), rod end bearings, ball bearings, PTFE tubing, IR photoelectric switches, stepper motors, timing pulleys, timing belts. The majority of items should arrive within four weeks of ordering.
- Place orders for UK/EU suppliers by the end of March, with the longest lead-time items being ordered first. These are mainly the hot ends and the CNC machined panels.
- As soon as we know how many kits we need to produce, we will be able to work out how large our 3D printer battery needs to be. As this will form the most crucial aspect of our project timeline, the main focus is on this part of the plan. By assembling the printers for our 3d printing battery, we will effectively be able to assemble the production version of our kits for the first time. This will be the moment to compile the Build Instructions for the kits, whilst being able to detect any problems and issues in time to rectify them. To take place during June/July.
Risks and challenges
Our team is experienced in managing complex projects to tight timelines and within budget. Richard Tegelbeckers, the main driving force behind the project, has been involved in many high profile projects. Amongst these are large scale machine building projects in the steel and manufacturing industry, involving complex planning, strict deadlines, little room for error, and high stakes. Richard's dictionary does not contain the word 'stress' and he is the kind of guy who eats problems for breakfast!
There are a few potential issues, which could have an adverse effect on our timeline. These include, but are not limited to the following:
The most crucial stage of the project is to get a 3D printer battery up and running in time to produce all the 3D printed parts for the kits. Depending on the way the KS campaign progresses, we will already order up any crucial items for the battery from faster (=more expensive) sources. If we are really in need for this, we can also call upon the help of a few local 3D printer owners to help with printing the necessary parts for the battery.
We rely on an external company to supply us with hot end kits. We received a verbal quote for the supply, but we will need to confirm actual timelines after we have established the actual numbers we require. As the hot end design is Open Source, there is always the option to take on the production of the hot ends ourselves. In actual terms this would lead to using our contacts, for having components machined in external machine shops. We have no reason to believe the original hot end manufacturer cannot fulfill our future order, but it is always good to have a plan B!
Whatever happens in terms of kit volumes required, we can call upon a flexible workforce to help us in getting all the work done. This workforce consists mainly out of peoples we already know, eliminating the potential problems arising with hiring complete strangers for temporary work.
International shipping is very complicated. We already did put a lot of effort in working out any potential issues beforehand and we have been in close contact with our local DHL depot from an early stage.Learn about accountability on Kickstarter
I want to know, what makes your printer different ?. Iv'e seen a lot of 3D printers pop up on Kickstarter lately but I want to know what sets your printer a part.
Our Open Source printer is based on a delta robot, known for it's use in pick and place operations. Due to the light end effector, it can move very fast. All heavy parts such as motors are stationary, as is the part being printed. The frame is self-aligning by design and very easy to assemble. Being very sturdy, the printer does not require frequent calibration. Also, a reduced numbers of components, good cable management and good design practice leads to a machine which looks good in a design office. As materials ABS and PLA have been tested, with the machine accepting coils up to 1kg from any manufacturer. Finally, the use of quality components, such as German made Igus linear slides, ensure durability and a reliable operation. The focus with the printer has been for out right performance, high quality, and pleasing aesthetics, with the cost factor being of secondary importance.
So far, the highest speed we have been printing at is 150 mm/s for infill speed and 250 mm/s for travel speed.
You will need several tools to complete a comprehensive kit:
- cross head (pozidriv) screw driver
- small allen (hex) keys
- terminal screw driver
- multi meter
Optional, but recommended:
- Electric drill and/or electric screw driver plus pozidriv bit.
The build area is 275mm in diameter and 250mm + high. If you were to print a rocket, the highest point of the rocket could be a bit higher than the 250mm.
Without the coil holder, the printer is 491mm wide, 500mm deep, and 758mm high. The detachable coil holder can be mounted on the top or the side, making the printer higher or wider.
The kits will come with a 0.3mm nozzle AND a 0.5mm nozzle, so you can choose yourself which one to use.
That would be our company logo. The 'wonky cross' is the nordic rune 'Nauthiz', which represents necessity. As necessity is the mother of all inventions, it fits in well with the design-driven and solution based approach of Tegelbeckers Ltd.
After the Kickstarter finishes successfully and you would receive a kit, you will be able to choose between having the printed parts made by us, or alternatively you can choose to receive some of our high quality material for printing by yourself!
Earlier this month we showed off our printer on the Develop3D live event in the UK: http://www.develop3dlive.com/ At the event, the suggestion was made that we would be able to sell the printer for double the price. At some stage someone walked up to us and said: 'so this is the stupidly cheap printer everyone is talking about'. By seeing the printer in real life, it can be appreciated for what it is, which is also the reason we ended up bringing it to the exhibition.
The Bill Of Material for the initial plywood prototype can be found in step 6 of my Instructable: http://www.instructables.com/id/DeltaTrix-3D-Printer/
The offered printer on Kickstarter differs in several ways, amongst others:
- The frame material is now treated Valchromat.
- The electronics are now based on the RUMBA board, being a higher spec alternative to the earlier RAMPS solution.
- New stepper drivers are now 1/32 microstepping.
- The stepper motors now have double the resolution, ie. 400 steps per revolution.
- Carbon fibre rods and tension springs replace steel rods and rubber bands.
- The square bed has been replaced with a round bed, featuring a purpose made silicon heater pad. This upgrade in itself costs us in the order of £50.
- The power supply is now a 400Watt unit, featuring our own purpose-made cover.
- Improved LCD surround.
- Proper connectors are used for the quick change print head and the new heated bed. As proper crimping tools would be needed for fitting the connectors, we will supply complete cable looms for Kickstarter.
See the following links to get an idea of the costs involved for some of our components:
Igus rail (600mm long|) and carriage, 3 off.
Male rod ends for carbon rods, 12 off.
ReprapPro Hot end, 1 off + extra nozzle.
A lot of our cost is in the CNC machined frame components, which we are offering for £125 as a separate set. If we are only meeting our minimal target, we would only just be able to break even on this as there are setup costs involved and CNC machining is not the cheapest option for producing stuff (see CNC machined ibook for reference...). As the resulting frame is very sturdy (no shaking during high speed printing!) and the finish is so stunning, we feel it is well worth the expense.
The price of our printer kit is higher than the cheapest around as we use high quality components and we do not cut corners on any aspect. Anyone in the market for the cheapest printer possible should skip ours. We would like to target the most demanding maker and the professional design engineer, who appreciate high performance, quality, and inspiring design.
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