Delta Rod Miter

thingiverse

Here is another in a series of tools I'm making to let you create your Delta printer from scratch. This one's a Parametized Opticoupler Break Carriage Bracket, designed for 2020 aluminum extrusion. With this tool, you tell it how long your connecting parts should be, and it'll give you measurements for the rod length you want. It'll also build the miter box and give you a measurement to offset the mounting versus cutting brackets. See the other items in this series: Parametized Delta Rod Miter: http://www.thingiverse.com/thing:1218870 Print Settings: Printer: Davinci 1.0a Repetier Customized Rafts: No Supports: No Resolution: .3 Infill: 20 Notes: Just about any printer should be able to print these without issues. Infill is not that important as these are not load-bearing, and the blade won't be in contact long enough to destroy them. How I Designed This Measurements and then even more measurements. As with all of my parts, these are modeled after real-world tools, ideas, and measurements using a caliper, feeler gauges, and other tools. Custom Section Objectives The usage of this part will provide the student with a method to replicate Delta rods to exacting measurements using real-world processes to measure, print, assemble, and finally cut rods to the size needed. These rods are designed around the standard Delta, which uses Traxxas bearing units or replacement igus bearings, that are screwed onto posts that are glued into the carbon fiber rods. Audiences This is for any student working with rods that need to be cut to exacting lengths. While designed for a Delta rod system, it could be extended to anything that needs rods to be cut to length. Since there are saw blades, cutting actions, and carbon dust created using this process, adult supervision is recommended for those who shouldn't handle these types of objects. Carbon Fiber Safety: http://www.carbonfiber.gr.jp/english/material/safety.html Preparation Find the data for the following options in order to have the proper data to create your rods with: printerTipWidth (the smear width, not the nozzle width; this is for slightly adjusting hole sizes) desiredRodLength (how long the completed rods should be; these are the ready-to-install rod lengths) rodDiameter rodTolerance Steps! Obtain all parts as needed from Preparation above. Customize the scripts based on the data gathered in Preparation above, and generate the required parts based on your settings. Obtain the measurement values that are returned by the OpenScad scripts for the miter box offset (ie, ECHO: "Mount the mounting bracket and then measure this far to mount the cutting bracket" ECHO: 180.75) Print all parts needed, only one set is needed to do multiple rods as they only take a few seconds to complete Mount the mounting bracket (single hole in upright) Measure the distance provided by the script and mount the cutting block (dual holes) securing it with the post insert nuts Insert the rod into the cutting block pushing it all the way through and into the mounting block. Use the cutout in the mounting bracket to visually ensure that the rod is inserted all the way into the hole. Place the blade into the cutting bracket, while holding the rod in place and smoothly cut through the rod using the blade. After a few seconds the blade should cut completely through the rod. Look at the pictures supplied to see this in practice. Remove the rod and set aside, repeat this process until all the rods you need are completely cut through Using the M3 rod (cut to 1 inch pieces) or the M3 bolts, drop some glue onto the threads and screw them into the rods about half way. The rods should have about half the screw sticking out. Snip the end off of the screw with a pair of large snips. Results Once completed, your rods should all be exactly the length that are needed. If the process was followed properly, all the rods should be the same length. Pictures are provided which show the proper cutting process, the measuring process and the end results. Following along with the instructions will ensure that your rods come out perfect every time.