A prototype is a preliminary model of something. Projects that offer physical products need to show backers documentation of a working prototype. This gallery features photos, videos, and other visual documentation that will give backers a sense of what’s been accomplished so far and what’s left to do. Though the development process can vary for each project, these are the stages we typically see:
Proof of Concept
Explorations that test ideas and functionality.
Demonstrates the functionality of the final product, but looks different.
Looks like the final product, but is not functional.
Appearance and function match the final product, but is made with different manufacturing methods.
Appearance, function, and manufacturing methods match the final product.
What is Abbycus?
Abbycus is a highly experienced engineering service with a background in supplying custom designed and printed 3D components to commercial and industrial markets. A few examples of our custom designs include camera and flight components for the drone industry, outdoor solar lighting designs, specialized plastic injection equipment, custom rapid assembly parts for PVC pipe projects, hard-to-find replacement parts for automobiles and appliances, and of course custom designed parts for our own 3D printers.
Some component designs and exotic materials proved very difficult with the 3D printers that were generally available on the market so we decided to design our own printers to improve quality, usability, and fill the needs of our customers.
The Abbycus 2020 is a no-compromise machine of the highest quality and performance that can achieve precision prints, reliable and fast operation, minimal maintenance, and with the ability to print almost every available filament material. We now wish to grow this part of our business by offering our printer at a very competitive price.
2020 printer-capable materials include standard PLA/ABS, various blends of NYLON (strong & low friction), POLYCARBONATE (super strong), PETG or Taulman TECH-G (strong and optically clear), POLYURETHANE / TPU (flexible, rubber like), POM (similar to Delrin), Carbon Fiber and metal infused filaments, glow in the dark plastics, and many others. The list of available thermoplastics for FDM printers continues to grow.
What is an FDM 3D printer?
Fused Deposition Modeling (FDM) constructs 3D objects by depositing thin layers of heated thermoplastic material. Each new layer thermally fuses to the previous layer resulting in a strong and accurate finished product.
Of the various technologies, FDM is arguably the most mature and easiest to set up and use. Quality prints are achievable in most environments.
The large selection of low cost thermoplastic materials for FDM printers satisfies a much broader spectrum of applications than resin based printers (SLA). Also no post-processing equipment is necessary.
And last but not least, FDM printing enjoys a huge support community. Countless articles on materials and troubleshooting print problems are easily located.
Abbycus 2020 Construction Details
Robust and rigid black anodized 20x20mm aluminum extruded frame features ease of maintenance, fast upgrade, and simple open build customization.
All printed components are printed on identical 2020 machines. Parts for the 2020 are printed from ABS, Nylon, TPU, and Polycarbonate for high strength and tolerance to high temperatures.
Frame leveling adjust knobs at each corner provides sure footing on uneven surfaces.
Smooth linear motion via high quality stainless smooth rod & linear ball bearings.
Z axis movement utilizes twin synchronous 8mm CNC type trapezoidal leadscrew's for fast Z height change, accuracy, and repeatability. No Z-axis resonance as compared to single leadscrew 'diving board' designs.
XY travel speeds up to 300mm/sec.
XY axis resolution = 0.01mm, repeatability = 0.05 millimeters. Z axis resolution = 0.000625 mm, repeatability = 0.025 millimeters.
Build volume: 200 x 200 x 200 millimeters.
COREXY positioning system with non-overlapping belt paths insures high accuracy, reliability, high speed, and reduced printing artifacts compared to more traditional Cartesian positioning systems. All drive motors are stationary.
Extruder type: Direct design with super grip filament drive gear handles all materials including plastics such as polyurethane (TPU) and slippery Nylon filament. The enclosed filament path helps prevent flexible filaments from escaping and jamming the extruder.
Hot end: E3D V6 Full all metal. Nozzle temperature to 300C.
Stainless steel nozzle resists abrasion from destructive filaments (carbon fiber, metal impregnated, etc.).
Hot end temperature sensor: PT-100 with 3-wire amplifier. Usable up to 480C and more accurate than NTC type thermistors.
500W heated build bed up to 160C. Heats from ambient to 110C in less than 5 minutes.
Control electronics board: Ultimaker RamBo v1.3 featuring embedded heater / fan drivers and 1/16 step stepper motor drivers with firmware current control.
Auto bed leveling system using the BLTouch hall effect Z Probe sensor. Repeatability to 0.075 mm.
Enclosed chamber using 3mm clear acrylic panels reduces print anomalies and warpage caused by stray air currents and helps maintain a more even chamber temperature during the print job. They also serve to reduce operational noise.
High intensity bright white LED bar illuminates build space and filament extruder assembly.
Filament management system prevents jams and prevents reel unwinding.
Separate part cooling fan and duct for use with PLA and similar materials.
Custom & optimized fork of the popular Marlin control firmware is open source and available on Github.
Purchase the optional Raspberry Pi 3 wireless host for standalone and/or wireless network control of your print jobs. The OS and applications are pre-configured on a 16Gb micro SD card. The choices are as follows:
For local operation, connect a HDMI display and USB keyboard & mouse to form a complete manually operated system with maximum control and flexibility. The standalone system also supports file sharing with other computers through your wireless network. The OS for the standalone system uses the Raspbian version of Debian Linux. Also included is the latest version of the popular open-source 'Printrun' printer control software.
WIRELESS REMOTE CONTROL
The SD card is pre-loaded with the latest version of 'OctoPi' which is built specifically for the Raspberry Pi SBC allowing multi-node printer control. Please visit https://octoprint.org/download/ for more information.
What is the state of the development?
The Abbycus 2020 is not an idea or a proof of concept. This printer is fully developed, tested, and functional. These printers have been running daily in our shop as a production workhorse since November of 2016 and have undergone numerous improvements. The design has proven itself to be robust, accurate, fast, and reliable. We are now prepared to offer this industrial level 3D FDM printer at a very competitive price here on KickStarter.
Where do the funds go?
Funds from KickStarter backers goes toward the following:
Volume purchase of all materials and sub-assemblies.
Purchase of manufacturing equipment & tools.
Completion of all documentation including a complete user guide.
Refinements of construction techniques and simplification of printed parts.
Refinement of assembly components including 3D printed parts.
Improve wiring harness for ease of assembly & maintenance.
Create user manual and related documentation.
Complete bill of materials (BOM) and approved vendor list (AVL).
Future Enhancement Ideas
Paste extruder system allowing 3D prints using silicone or other paste materials.
Laser etching/cutting head can be swapped with the 3D print head.
Risks and challenges
Due to the complete and proven state of our design, we do not anticipate any significant risks.
Anticipated challenges will be in purchasing quantities of materials, developing the manufacturing process, and creating high quality user documentation.
NOTE: This is an add-on option to your purchased printer and is purchased separately. The Raspberry Pi host will be embedded and delivered with your printer.
The Raspberry Pi host option provides standalone operation with Wifi file sharing or remote control of your print jobs using Octoprint.
Raspberry Pi 3 Model B SBC mounted in printer.
SD Card, 16Gb. Pre-configured as standalone or Octoprint.