Replicator 1 Transformation

thingiverse

I initially encountered numerous minor issues affecting quality and consistency when I started using the Replicator. This account recounts my efforts to resolve these problems. The most recent addition is a front door, which I've attached with hinges already posted here: http://www.thingiverse.com/thing:47591. DXF files for acrylic covers are also included. My Replicator 1 underwent several modifications and fixes from the moment it printed its first item. I decided to rebuild it with a solid, rigid structure, addressing issues one by one. I wasn't satisfied with the plywood frame due to reasons like rigidity, resonance, noise, temperature control, fan noise, print head alignment, and temperature distribution on the build plate, along with firmware-related concerns. I started by modifying original drawings for a new framework, which was laser-cut from 6mm black acrylic, improving noise and accuracy. The top and bottom panels were cut in 6mm aluminum for added rigidity. Reinforcing the HPB support arms led to adjustments in print head travel limits, reducing build cube size but increasing platform stability. A 5mm aluminum HPB with modified springs was added for consistent tension. Next on the list is experimenting with glass and adding a three-point levelling system, thanks to guidance from Mecano (http://www.thingiverse.com/thing:42756). Despite ongoing improvements, the process is time-consuming and dependent on day job availability. However, consistent, accurate prints are now achievable, with further enhancements expected through collaboration with fellow 3D printing enthusiasts. A video demonstration can be viewed here: http://youtu.be/ncM7SWQdnxY. All necessary files for the full housing, including side covers, are included. The front cover will be added once it's designed. MP2195 (bottom panel) remains unmodified as no changes were made to it.