Spoked Bike Wheel

thingiverse

To successfully print a bike wheel spoke on Mendel (0.5 nozzle) using ABS, I utilized SCAD to generate the various components and then manually combined them. The entire process was documented in a YouTube video available at http://www.youtube.com/watch?v=j69QjNhJAVU. However, this task requires advanced skills as it involves editing the g-code for better results. For those interested, I have uploaded both the scad script and the generated g-code files. Note that the g-code may not work on other machines but can serve as a reference. The process used to achieve this was quite involved. It started with generating stl files for each component using the scad script, ensuring that spokes were printed flat to slice in one layer. Next, g-code was generated for each stl file using ReplicatorG and skeinforge40, while maintaining the same settings. The stl files, excluding the first hub and rim, were sliced in mid-air to avoid changing layer heights during merging. Then, the g-code file for the first hub and rim was opened, and comments were added to identify joins. In turn, each additional stl file's printing code (without initialization, raft, support, or ending) was copied into the new file, accompanied by comments for easy identification. The order was: hub and rim, spoke1, spoke2, center hub, spoke3, spoke4, outer hub, and half-rim. At each join, E values were corrected, and retraction values were adjusted when necessary. For the spokes, Z values at both ends were modified to ensure proper alignment with the corresponding layers. Feed rates had to be reduced for each spoke based on the printer's capabilities through trial and error (F250 value worked well). Lastly, additional g-code was added to prevent the head from damaging the spokes during the second rim print, as it was lower than the center hub.