The metalFunk 3D Printer
When a one year project is solved years in the furture
The Evolution of metalFunk
The metalFunk 3D printer has undergone several name changes since its inception. It started as A3D-One when I was 16, reflecting my early ambition and enthusiasm. Later, it became MetalHunk due to its robust, full-metal frame—its most impressive feature. Now, it’s called MetalFunk, a nod to the challenges and quirks that have come with building it, while also embracing a funky, more light-hearted spirit.
The Begining
Designing this 3D printer has been an enlightening experience, though not without its frustrations. What began as a teenage project has turned into a long-term endeavor, teaching me valuable lessons in engineering and perseverance. Here’s a look at what this journey has entailed:
- Investment: Approximately $400 initially, plus an additional $100 for modifications and troubleshooting.
- Challenges: Numerous, including complex technical issues and the learning curve of working with limited knowledge.
- Unique Goal: To create a 3D printer that no one else in the world has—a unique testament to my dedication and creativity.
Key Specs and Features
- Frame: Built entirely from 2040 and 2020 T-Slot aluminum extrusion profiles, making it incredibly sturdy.
- Extruders: Includes a BMG Bowden extruder and a custom slim extruder for the Ender/CR Hotend.
- Electronics: Currently runs on the classic Ramps 1.4 with an Arduino Mega, with plans to upgrade to either the Ender 3 - 4.2.7 Non-Silent Board or the BIGTREETECH SKR Mini E3 V3.0.
- Firmware: Utilizes Marlin 2.0.1, featuring a double Z-axis for enhanced stability.
- Future Improvements: Plans to incorporate V-Roller based kinematics and other modern features.
Current Status (As of March 2024)
- Frame: Solid and usable.
- Movement: Operational, though previously it wasn’t.
- Safety: No longer prone to catching fire, a significant improvement.
- Print Quality: Currently subpar, with major issues including layer skipping and motor overheating.
Development Challenges
- Layer Skipping: The printer struggles with layer skipping on prints longer than 40 minutes, rendering them unusable.
- Motor Currents: The Nema 17 motors (17HS3401) overheat at their rated 1.2 amps, requiring careful current management.
Uploaded CAD File
The CAD file includes the metal frame and motors/endstops. All plastic components need to be redesigned from scratch.
Goals and To-Do List
- Redesign and Reprint Plastic Parts: Every piece of 3D printed material needs to be updated from the Frankenstein adaptation I initially created.
- Upgrade the Control Board: Replace the outdated Ramps 1.4 with a more reliable and modern board.
- Achieve Reliable Printing: With a new board and redesigned parts, consistent and reliable printing should be attainable.
- Enhance the Extruder: Improve aesthetics, add a cooling fan, lighting, and better cable management.
- Improve Aesthetics: Give the printer a more polished and professional look, infusing it with personality.
- Incorporate V-Roller Kinematics: Update the motion system to modern standards, eliminating the use of smooth rods and linear bearings.
- Future Innovations: Aim for high speeds, quiet operation, wireless connectivity, and other advanced features.
Timeline and Future Outlook
I aim to achieve at least objective #4 by Summer 2024. However, as a busy Electronics Engineering and Computer Science student, I’m not imposing a strict deadline. If by August 2024, the printer isn’t reliably printing, I may consider scrapping the project due to unsustainable value.
Man Hours Logged
- 2019-2020: 50+ hours
- Dec 2023 - Jan 2024: 20+ hours
- March 2024 (Holy Week): 10+ hours
- Total: ~80+ hours
Stay tuned for more updates on the metalFu(n)k 3D printer as I continue to refine and improve this unique creation.