Monthly Archives: December 2020

3D Modeling: Elegant Pieces in OpenSCAD with rcube(), rcylinder() and chainhull()

by Rene K. Mueller · published December 28, 2020 Art, Technology Chain Hull, OpenSCAD, Parametric CAD, Rounded Cube, Rounded Cylinder

Updates:

2020/12/31: rcube() extended, RCUBE_FLAT{BOTTOM, TOP, FRONT, BACK, LEFT, RIGHT} support added, rcylinder() with RCYLINDER_FLAT{TOP, BOTTOM}
2020/12/30: rcube() source code extended, support RCUBE_FLATX, RCUBE_FLATY, RCUBE_FLATZ
2020/12/28: inital post

While working on Ashtar D (Classic XY) I looked at some pieces I rushed to design with cube() and hull() and they didn’t appeal to me – yes, it kind of hurt my eyes.

A while back I coded a simple rcube([x,y,z],r) which takes r as a radius for the edges, internally it’s an OpenSCAD module which uses 8 spheres and hulls them together, providing round edges; but I hesitated to actually use it in my designs – until now. Further I thought, let’s do the same with cylinder() using rcylinder(d=10,h=5,r=1) providing round edges by using two torii and hull them together.

These two new functions, rcube([x,y,z],r) and rcylinder(h,d,r) allow to create more organic and elegant pieces, see for yourself:

From Bulky To Elegance

The position of the Y pulley mount is given, a bit of an X- & Y-offset to ensure printable area is not sacrificed for the Y carriage:

Using Chained Hulls

And another example . . . replacing hull() with chainhull():

The final version is composed by only 3 pieces chain hulled together:

difference() {
   chainhull() {
      rcylinder(...);
      translate([0,0,-20]) rcube(...);
      translate([...,-60]) rcube([5,20,50],2); // 2020 mount plate
   }
   rcube(...);     // pulley cutout
}

rcube() & rcylinder()

rcube();
translate([5,0,0]) rcube(0.75);
translate([10,0,0]) rcube([2,1,1],0.2);

translate([0,2,0]) rcube([2,1,1],0.2,false);
translate([5,2,0]) rcube([2,1,1],0.2,true);

translate([0,4,0]) rcube([2,1,1],0.2,RCUBE_FLATX);
translate([5,4,0]) rcube([2,1,1],0.2,RCUBE_FLATY);
translate([10,4,0]) rcube([2,1,1],0.2,RCUBE_FLATZ);

translate([0,6,0]) rcube([2,1,1],0.2,RCUBE_FLATBOTTOM);
translate([5,6,0]) rcube([2,1,1],0.2,RCUBE_FLATTOP);

translate([0,8,0]) rcube([2,1,1],0.2,RCUBE_FLATFRONT);
translate([5,8,0]) rcube([2,1,1],0.2,RCUBE_FLATBACK);

translate([0,10,0]) rcube([2,1,1],0.2,RCUBE_FLATLEFT);
translate([5,10,0]) rcube([2,1,1],0.2,RCUBE_FLATRIGHT);

translate([0+1,14,0]) rcylinder(3,1.5,0.2);
translate([3+1,14,0]) rcylinder(3,1.5,0.2,false);
translate([6+1,14,0]) rcylinder(3,1.5,0.2,RCYLINDER_FLATBOTTOM);
translate([9+1,14,0]) rcylinder(3,1.5,0.2,RCYLINDER_FLATTOP);

The library code (I might later release it as a separate library):

// Title: rcube(), rcylinder() & torus()
// Author: Rene K. Mueller
// License: MIT License 2020
// Version: 0.0.2

RCUBE_FLATX = [false,true,true];
RCUBE_FLATY = [true,false,true];
RCUBE_FLATZ = [true,true,false];
RCUBE_FLATBOTTOM = [false,false,false,false,true,true,true,true];
RCUBE_FLATTOP = [true,true,true,true,false,false,false,false];
RCUBE_FLATFRONT = [false,false,true,true,false,false,true,true];
RCUBE_FLATBACK = [true,true,false,false,true,true,false,false];
RCUBE_FLATLEFT = [false,true,true,false,false,true,true,false];
RCUBE_FLATRIGHT = [true,false,false,true,true,false,false,true];

module rcube(a=1,r=0.1,rd=[true,true,true],center=false,$fn=32) {
    if(FAST_RCUBE)
       cube(a);
    else {
       x = len(a) ? a[0] : a;
       y = len(a) ? a[1] : a;
       z = len(a) ? a[2] : a;
       rd = len(rd) ? rd : [rd,rd,rd];

          if((len(rd)==3 && rd[0] && rd[1] && rd[2]) || (len(a)==0 && rd)) // rd=[true,true,true] or true
             hull() {
                translate([r,r,r]) sphere(r);
                translate([x-r,r,r]) sphere(r);
                translate([x-r,y-r,r]) sphere(r);
                translate([r,y-r,r]) sphere(r);
                translate([r,r,z-r]) sphere(r);
                translate([x-r,r,z-r]) sphere(r);
                translate([x-r,y-r,z-r]) sphere(r);
                translate([r,y-r,z-r]) sphere(r);
             } 
          else                                                        // anything else
             hull() {
                translate([r,r,r]) rcube_prim(r,rd,0);
                translate([x-r,r,r]) rcube_prim(r,rd,1);
                translate([x-r,y-r,r]) rcube_prim(r,rd,2);
                translate([r,y-r,r]) rcube_prim(r,rd,3);
                translate([r,r,z-r]) rcube_prim(r,rd,4);
                translate([x-r,r,z-r]) rcube_prim(r,rd,5);
                translate([x-r,y-r,z-r]) rcube_prim(r,rd,6);
                translate([r,y-r,z-r]) rcube_prim(r,rd,7);
             }
    }
 } 

module rcube_prim(r,rd,i) {
    a = len(rd);
    if(a<=3) {
       if(a && rd[0] && rd[1] && rd[2]) 
          sphere(r);
       else if(a && rd[0] && rd[1])
          translate([0,0,-r]) cylinder(r=r,h=r*2);
       else if(a && rd[1] && rd[2])
          translate([-r,0,0]) rotate([0,90,0]) cylinder(r=r,h=r*2);
       else if(a && rd[0] && rd[2])
          translate([0,-r,0]) rotate([-90,0,0]) cylinder(r=r,h=r*2);
       else
          translate([-r,-r,-r]) cube(r*2);
    } else 
       if(rd[i]) 
          sphere(r);
       else 
          translate([-r,-r,-r]) cube(r*2);
 }

RCYLINDER_FLATBOTTOM = [false,true];
RCYLINDER_FLATTOP = [true,false];

module rcylinder(h=2,d=1,r=0.1,rd=[true,true],$fn=40) {
    if(FAST_RCYLINDER)
       cylinder(d=d,h=h);
    else
       hull() { 
          translate([0,0,r]) 
             if(len(rd) && rd[0]) torus(do=d,di=r*2); else translate([0,0,-r]) cylinder(d=d,h=r);          
          translate([0,0,h-r]) 
             if(len(rd) && rd[1]) torus(do=d,di=r*2); else cylinder(d=d,h=r);
       }
 }

 module torus(do=2,di=0.1,a=360) {
    rotate_extrude(convexity=10,angle=a) {
       translate([do/2-di/2,0,0]) circle(d=di,$fn=20);
    }
 }

chainhull()

module chainhull() {
    for(i=[0:1:$children-2])
       hull() {
          children(i);
          children(i+1);
       }
 }

There is one drawback using chainhull() { } as you can’t use conditional if else with { } within as it combines them as a group and becomes a child structure and so it will act as hull(), so you only can list non-conditional pieces within chainhull() as of OpenSCAD 2019.05, perhaps at a later time this limit vanishes.

That’s it.

3D Printer Ashtar D: Classic XY, First Draft

by Rene K. Mueller · published December 25, 2020 Technology 2020, 2020 Alu Extrusion, Ashtar D, Ashtar D 3D Printer, Cubic Frame, RepRap

After the Core XY implementation of Ashtar C I pondered on changing the kinematic to a more classic approach to separate X and Y axis motors, but otherwise keep the setup and frame, hence Ashtar D:

Ashtar D: classic independent XY kinematic: head XY, bed Z setup, with 500mm 2020 alu profiles

Draft

Again using 500mm alu profiles, utilizing the frame itself as rails:

1 V-slot beam for X axis with V-carriage/module (triangle shaped carriage) as X carriage with hotend
2 V-slot beams for Y axis, 2 V-carriages/modules with the X beams on it
- using classic V wheels
14 T-slot beams for the rest of the frame
- Z bed: white 7.3mm thick Delrin wheels on T-slots

The target is again a 400x400mm printbed, probably 380x400x380mm build volume alike with Ashtar C (Core XY), perhaps a bit less X-wise due the more complex pieces to mount the X motor and pulleys.

More high resolution renderings:

The project page on Ashtar D summarizes the current state of the project.

3D Printer Ashtar B: Cantilever, First Draft

by Rene K. Mueller · published December 23, 2020 Technology 2020, 2020 Alu Extrusion, 3D Printer, Ashtar B, Ashtar B 3D Printer, Cantilever, OpenSCAD, RepRap

It has been on my mind for quite a while to do a 2020 alu extrusion based Cantilever 3D printer, and so I started in December 2020 with a rough design, starting from the existing Ashtar K design and cut away parts:

using Head XZ and Bed Y
aiming common build volume (e.g. easy to source print bed)
- 140mm to 190mm each axis
tried 6, 7 and 9 beams options, settling with 6 beams for now
aiming for uni-length 2020 alu extrusions, T-slot and V-slot where a carriage rides (X & Z axis) with V wheels.
trying to keep as simple as possible

20×20 aka 2020 Alu Extrusion T-Slot Profile

Frame: 6 vs 7 vs 9 beams

The 9 beams give an overall better sturdiness, but not sure how essential at small building volume (less than 220mm each axis). I might be able to remove beam, the last beam at the back at the bottom reducing to only 6 beams, in that case the Y motor is mounted on the remaining beam in the back.

Z Carriage: 3 vs 4 wheels module

The 4 wheels looks best but it also sacrifices some of the X range by apprx. 10mm, the obvious choice is 3-wide mount – actual tests will tell if the X & Z axis are solid enough.

Different Sizes

The 200mm build axis length would be good, but I’m not sure if the XZ carriage will allow it as the max margin or tolerance would be half of a layer-height, e.g. 1mm layer height ⇒ 0.05mm tolerance, at X = 0 .. max the head should not flex more than 0.05mm. At this this early draft stage I don’t know which size is most suitable, I focus on 180mm build axis.

The project page on Ashtar B summarizes the current state.

3D Printer Ashtar M: Moving XZ Frame (Moving Gantry), First Draft

by Rene K. Mueller · published December 14, 2020 Technology 2020 Alu Extrusion, 3D Printer, Ashtar M, Ashtar M 3D Printer, Draft, Moving Gantry, Moving Portal, Moving XZ Frame, OpenSCAD, RepRap

Updates:

2020/12/20: adding XZ arch option
2020/12/14: initial post

In April 2020 Jon Schone (@properprinting) showed a “Moving Portal” mod for his CR-10 – a Prusa i3 derivative – and I thought to adapt his approach as “Ashtar M” as moving XZ frame or moving gantry in CNC terms.

On a second thought, this approach makes only sense with larger beds, as the bed weight should exceed the weight of XZ frame and X carriage:

weight(XZ frame + X carriage) < weight(bed)

and as I compose my Ashtar 3D printer series with alu extrusions (beams) I can say:

weight(XZ frame) = beam X * 2 + beam Z * 2 + NEMA17 * 2
weight(bed) = X * Y

and it becomes here clear, the bed weight grows X * Y whereas XZ frame only (X + Z) * 2, but also 2* NEMA17 motors of the Z axis are part of the XZ frame.

Moving Portal / Gantry

A few still images of Jon’s YT video to look at some details of his approach:

First Draft

using solely 500mm 2020 alu extrusions (T-slot for general frame and XZ frame, V-slot for carriages: X beam, 2x Y beams)
trying to achieve 400x400x400mm build volume as close as possible, alike Ashtar C 38.40.36

Using for Y carriages existing vcarriage2 module with vcarriage2(width=100) to have it wide enough:

The two main new pieces required were connecting the Y carriage with the XZ frame:

Piece “A” outside ycarriage_xzframe_mount_a(): has to be printed with 0.1mm layer height in order to stay within the +/- 0.05mm tolerance, otherwise it will introduce tilt and stress on the Y carriage and cause long term damage – tricky part to print.

Piece “B” inside ycarriage_xzframe_mount_b(): is quite elaborate already and should be functional, with the Y belt ends fastening with M3 screws and M3 nuts inserts, the belt endings will come out downward:

XZ Arch Option – Removing Lower X Beam

In order to gain some Z build space by lowering the print bed, I may reduce the XZ frame to an XZ arch:

Side pieces “A” & “B” with Arch (lower X-beam removed)

Actual physical tests may reveal if it’s suitable to maintain overall geometrical integrity. Removing the lower X beam also reduces moving mass of the XZ arch/frame/gantry.

Pros

gain Z build space
reduce XZ gantry weight / inertia

Cons

decrease XZ gantry stability

Further Development

As I develop Ashtar M further, I will post updates on the blog here, and also keep documenting the current state at Ashtar M page.

That’s it.

Infinite-Z CR-30 aka 3DPrintMill: Creality Acknowledges Prior Development & Commits to Open Source (2020/12)

by Rene K. Mueller · published December 8, 2020 Technology 3DPrintMill, Adrian Bowyer, Belt-based Printer, Bill Steele, CR-30, Creality, Infinite Z, Karl Brown, Naomi Wu

As of December 2020, something remarkable has happened: Creality, a big chinese 3D Printer company has openly acknowledged and worked with western developers to bring forth a belt-based 3D printer.

Usually chinese companies have copied without acknowledge or give credit to development done by others like Adrian Bowyer or Josef Prusa, yet with the influence of Naomi Wu, a maker from Shenzen, Creality seemed to have been swayed to give proper attribution and even actively work with Open Source Hardware inventors to mass produce a belt-based 3D Printer.

CR-30 aka 3DPrintMIll by Naomi Wu with Creality (2020)

The past decades “Western Innovation vs Chinese Manufacturing” combo has been operating very well and brought many consumer products at low cost, including 3D printers.

Now, in this particular case, we see Bill Steele and Karl Brown (White Knight Printer) properly attributed in the 3DPrintMill Kickstarter page:

CR-30 Kickstarter [Screenshot 2020/12/08]

And even giving proper context of the overall lineage:

Lineage

All consumer 3D printers currently sold, build in some way on the work of Adrian Bowyer and his RepRap project- Open Source 3D printing. Some 3D printers iterate more than others, some are simply clones and claim innovations as their own that was in fact the community’s work. Others take only the broad strokes of an idea and build on it, improve it, and allow others to build on it further. For the 3DPrintMill (Creality CR-30) we have taken pains to involve and consult the talented individuals who brought the technology this far, and built on their work with their permission.

Bill Steele, who first demonstrated Infinite-Z FDM and DLP printers, and Karl Brown who created the first practical, Open Source kit so consumers could build their own Infinite-Z printer. Both Karl and Bill have given the project their blessing- and indeed, without them, it would never have been possible.

As said, this is remarkable and probably a new level of cooperation of Open Source Hardware movement and chinese manufacturers.

Back in 2010 I thought that the Open Source Hardware movement should actively seek cooperative alliance with chinese manufacturers instead just to complain – but this did not happen. Now in late 2020 it seems happening, thanks to Naomi Wu (Project Head for the CR-30/3DPrintMill), who made an effort to bridge the western innovation culture and chinese manufacturing culture – without a bridge, a canyon keeps villages apart.

Thanks also to Creality, namely Michael Tang (Co-founder of Creality), Steven Han (Brand Director), Zhou Yong (Product Manager), Lei Congjin (R & D Manager), Yu Xianhong (Project Manager) for the acknowledgment as expressed in the Kickstarter page.

Open Source Hardware Commitment

Additionally, and perhaps even more relevant is their on-going commitment to Open Source Hardware as expressed in this passage:

Bringing the 3DPrintMill (Creality CR-30) to life would need the resources of a full engineering team and a company with substantial 3D printer manufacturing experience. So a deal was struck, Creality would invest the R&D resources necessary to make the 3DPrintMill(Creality CR-30) real, and as soon as that expense was recouped, the entire product would be fully Open Sourced for the benefit of the community. When the 3DPrintMill (Creality CR-30) reaches 5 million USD in crowdfunding, the whole machine- CAD files, BOM, firmware, schematics, will be fully Open Sourced. Anyone in any country can make their own version, iterate and improve on it- leading to vastly accelerated development.

This is probably what many Open Source Hardware (OSHW) enthusiasts have been waiting for, one of the big player like Creality join the common OSHW efforts once more, after having released all plans of the Ender 3 in 2018 and giving an example for other companies.

Bigger Context

And I look at Apple, Microsoft, IBM, ARM, Intel, AMD and I wonder, with the Open Source ISA (Instruction Set Architecture) of RISC-V on the horizon, whether we are going to see the full stack of Open Source Hardware from the CPU design up to the PCB and final assembled computer (GPU, RAM, I/O); and if any of the big players take a moment, and look at what Creality did here?

Naomi Wu ranted away on Twitter with the following, which hits the nail about Open Source and Open Source Hardware is really about:

Software? Fusion360, Adobe Creative Cloud, John Deere tractors- a tradesperson can’t even own their own tools anymore. We’re all sharecroppers. Everything is rented.
…
Every single thing we own is being taken, put in the cloud, and rented back to us. Willingly. Because no one wants to know how to do anything beyond a narrow scope. We’re a world of carpenters willing to rent sharp chisels and saws rather than learn to sharpen them ourselves.
…

Although the rant started as people seemingly complained on the non-existing or poor customer support of Creality, her main argument is, rather have Open Source Hardware and a community helping each other, than a Closed Source without any control but good customer support – the rant actually targets the Software- & Hardware Sovereignty, which is behind all of the Open Source movement, that is the core issue: you are allowed, you are given the opportunity to improve what you bought, what you own, you can resolve the needs and requirements of your own use cases – personal evolution – and you contribute and help others by being able to share it again – collective evolution. And the mentioned companies, like Apple, or Microsoft, who have been locking up their hardware and software further and further, to improve usability and simplicity – and believe me, I have been an open critic of poor GUIs in Linux not able to catch up – but the price is high, loss of “digital sovereignty” as of software and hardware.

So, because companies are profit driven, they have to balance their own needs and requirements with the collective interest – and this is done in these statements:

Creality would invest the R&D resources necessary to make the 3DPrintMill(Creality CR-30) real, and as soon as that expense was recouped, the entire product would be fully Open Sourced for the benefit of the community.
When the 3DPrintMill (Creality CR-30) reaches 5 million USD in crowdfunding, the whole machine- CAD files, BOM, firmware, schematics, will be fully Open Sourced.

This is why I consider this an important and significant move, because a profit-driven company has actively and willingly balancing its own needs and requirements with those of the collective of the Open Source Hardware movement, and acknowledged that very product they are about to produce has been possible because of individuals like Adrian Bowyer, Bill Steele and Karl Brown.

Remarkable.

That’s it.

PS: If you are interested in early development 3D printers, see RepRap movement or general 3D Printer History.

XYZ dims *

3 Dimensions Explored – 3D-Modeling & 3D-Printing