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5/24/2017 Update

Finished school monday. Back on full time Went to redwood city techshop again and cut the gears. The gears were the first cuts using fusion 360 cam aka hsm works they had a weird twist in the gear i found out that that was because the arc in the plasma actually bends twords where the ground is and the twist was twords the ground clamp. the cam gcode was not plug and play. i had to modify it to work on torchmate. So i am going to go into more detail on what torchmate didn't like and make sure that that gcode is not outputted. However. fusion 360 still does not have nesting capabilities So i will try to use vcarve pro to do the gcode as it has nesting capabilities. I also had the chance to do varying speed lines on the plasma I did this to check to see ideal speeds to minimize dross which minimizes post cleanup. i started with 19 lines each with dropping speeds of 5 ipm with each line i found that 7 (70 - 40 ipm) of those lines had the least dross. i then put those into a array of 7 lines spread apart and cut them again to better see the dross more clearly and picked the best one i believe 65 ipm i plan on going back to tech shop redwood city tomorrow to cut out a full shredder to gauge the post cleanup. And also time the post cleanup i will be trying to use vcarve pro to do the nesting for the 4x12 plates of a36 to do an entire shredder. I will then try to assemble and see how it goes. However, i will be going on vacation with my family on Friday for 2 weeks. so i will only be working on the gcode from there. so if the a36 goes well i will pick up the 1045 plate from supplier and start cutting. I will also try to get the hardening option up on my store if anyone is interested in that. check below for more pictures.

Steven Mosbrucker

Steven Mosbrucker

 

73rd Week: 5/9/2017

Have been swamped with school projects, tests, hw, and finals. so i will not have prototype by maker fiare also i might not even be able to attend or show at maker faire as i have a very critical final on the 22nd the day after maker faire i just got in the hall effect sensors and the rare earth magnets so i will need to implement that code into the program as well summer is coming up on 5/25/2017 then i will be be back to the green engineers stuff however i will need to take a summer class and might do a internship to get some money to get a small place to organize my stuff again thanks for your patience check bellow for pictures  

Steven Mosbrucker

Steven Mosbrucker

 

Update: 5/8/2017

Cut some test pieces this weekend at tech shop redwood city They came out pretty good. except a few problems that will need to be adjusted I now need to come up with a better way of knocking off the dross/slag The software that generates the gcode at redwood city's torchmate is ancient and garbage I will need to figure out how to leverage fusion to get better cuts. and use vcarve pro 8.5 to do nesting into whatever size of plate i have next i will be working on modifying the fusion files to adapt what i learned from the test cuts next weekend i plan on cutting out an entire shredder in A36 for first steel prototype. check out bellow for all the pictures that i have taken from the cutting process. going to take some more close up shots of the parts i will add those when i take them
 

72nd Week: 5/3/2017

Started to fall behind in school a little bit so had to devote some more time to it. So haven't devoted much time int o project but i am going back into now. going to have a new printer in less than 10 days. i am building a 18" x 18" x 18" build volume printer out of the car case of my old kossel. Maker faire is coming up in 2 weeks. i actually have a final that monday after maker fair and i is a difficult class so i am not sure i am going to be able to make it. I will do what i can to make it to the faire and hopefully have a mock up there of the multistruder most of the 3d prints are ready to go i need to print another roller and glue the bearings into the pulley and both of the dimensional control rollers then assemble one
 

Update: 5/1/2017

I have taken the cnc plasma cutter class at tech shop redwood city. The cuts it does are quick but pretty rough and will need finishing by hand filing and buffing. However, i learned that tech shop redwood city also has a small heat treating oven for knives that looks like it would be big enough for at least one shredder at a time to heat treat then temper. I will be doing some testing on that with a gear that i cut and some hardness testing files to see what type of hardness i can put out. So i will work on a price and make that available for you guys as well. When i am done testing. I am going to be in contact with my supplier to tell them that i am going to be purchasing a 1/4 inch 1045 about 4"x4" sheet Also i am going to head out there this weekend with some A36 and do some test cuts as that should be pretty similar to the 1045. Also i will try to harden a piece of A36 and it probably wont work. we are really close to getting a prototype cut and finalized to run into production and possibly some heat treating of a few if you guys desire. Check out pictures bellow.
 

70th Week: 4/18/2017

Got in 30 metal bearings. Have been finalizing all of the rotating 3d printed pieces to use these bearings been getting some gorgeous prints off of my personal kossel 3d printer at home if printing very slowly. have updated the pulley and the dimensional control rollers to use the bearings so far I have purchased the hall effect sensors and some rare earth magnets to monitor rpm to check speed and also enhance the auto extrude algorithm. Trying to get a prototype built to premiere at Maker Faire Bay Area this year. event is may 20th Bellow you will see my prints that are using the new metal bearings bellow check out pictures bellow

Steven Mosbrucker

Steven Mosbrucker

 

Update: 4/15/2017

CNC Plasma Cutter Redwood City appointment coming up soon About time to purchase the plate of 1045 steel I machined the jig for the A36 for cutting out of the tormach It was machined out of HDPE Starboard. It is a jig to mount 2 4" x 12" x 1/4" A36 Plate to be cut and held down in the tormach. so when i swap in the next pair of A36 plate in i dont have to rehome the tormach plate purchase coming up. Bearings as well, as well as drive square bar. Stay tuned First cuts coming very soon. Check out pictures below. 

Steven Mosbrucker

Steven Mosbrucker

 

69th Week: 4/11/2017

Ordered the hall effect sensors and the magnets for rpm speed detection to better increase the percision of the automatic algorithm tech shop is back open going back to start printing the pieces after a final double check of the models. will also buy some more filament. Im going to try 3dxtech brand i think. bearings have not come in yet maker faire bay area is coming up and i will be a presenter there again this year. hopefully i will have the first one built and running before then. maker faire is in mid may alot more coming soon now that tech shop is back open. As my printer is just not reliable right now.

Steven Mosbrucker

Steven Mosbrucker

 

68th Week: 4/4/2017

TechShop is still closed. They failed an inspection so new reopen date is 4/5/2017 (tomorrow) instead of 4/1/2017 Bearings for dimensional control rollers,pulley have been purchased. I am going to try to get those to work with the spooler A lot of models edited im getting closer As stated in last blog the beta version of the software is finished so waiting to install on first unit Most of the rest of the printing will be completed at TechShop on the replicator 2 because as of right now it is more reliable than my printer at home. Now i am trying to source some rubber or cork to rap around the piece that drives the spool on the spooler module. I am also going to source some hall effect sensor. More pictures when i finalize more of the models and begin printing. or when i get in some of the stuff i purchased.

Steven Mosbrucker

Steven Mosbrucker

 

Update: 4/3/2017

TechShop is still closed. They failed one of their inspections so the re-open date has been pushed back to 4/5/2017 instead of 4/1/2017 I have signed up for the cnc plasma class. issue is that the closest class i was able to sign up for is 4/28/2017 I have been calling in for every class from now to 4/28/2017 if a seat come available that i could fill in between now and then. When TechShop San Jose reopens i will be moving forward with the template for the A36 shredders to be able to mill out. even though that process will take like 6-7 hours to make 1 shredder In the mean time i have been looking to buy some heavy duty flange bearings so i can adapt my model to accommodate them.  Then buy the square drive shafts for machining. Or source hexagon shafts

Steven Mosbrucker

Steven Mosbrucker

 

67th Week: 3/28/2017

On spring break. back to school on Monday redesigned a lot of the 3d models and printed alot of prototypes tech shop san jose is closed down for move to 2x bigger location re opening on april 1st  some models will need to be printed at techshop over night because of long print times software beta finished and ready to be installed decided to buy metal ball bearings from china so those are on the way and redesigning the models to accommodate those new bearings. now i need to buy some metal springs and thrust bearings and i think we are good to go. check out pictures bellow.

Steven Mosbrucker

Steven Mosbrucker

 

Update: 3/24/2017

Techshop San Jose is now closed for move to the new twice as large location I was preparing to machine a template for machining the 4" x 12" inch A36 plates. However something new came up Tech Shop Mid Peninsula in Redwood City just got the permits for their cnc plasma cutter to be used again This is a great development. This will decrease the time for cutting the shredder by about 11 times. which drastically increases my speed for production However one thing that I will have to deal with is the quality of cut. the quality of cut is not going to be as good as a water jet or the mill. As technically the plasma cnc cutter is the worst quality of cut all cnc machines. as plasma cnc machines are built for speed not quality of cut. The plasma cnc machine will leave dross. and more taper than the other cnc machines. so I'm predicting a lot more cleanup than the mill. qThe Bad is that the class to learn the machine is full until the 20th of next month. I am working to getting into a class or checked off on the machine asap. So I will be just buying the 1045 steel 4' x 8' x .25" plate (does 8.5 shredders). and start cutting. if everything checks out we are ready to rock and roll Again thanks for your guys patience. it is coming check out pictures bellow for some pictures of example cuts from the cnc plasma cutter.

Steven Mosbrucker

Steven Mosbrucker

 

66th Week: 3/21/2017

I will be finished with last part of code for beta today. Now Just double checking the 3d cad models and start printing them at home. I am now on spring break tell 4/3/2017 TechShop San Jose is now closed for move to twice as big facility. they will be back up in about 10 days back in new facility. We are still moving ahead. even more progress to happen while on spring break.

Steven Mosbrucker

Steven Mosbrucker

 

65th Week: 3/14/2017

Printed a whole bunch more of the dimensional control brackets Started to work on the code. i will do more this friday try to finalize a beta asap Need to source some springs for the dimensional control brackets only small pieces remain to be printed. I will be without tech shop from march 23rd for about 10 days. (As of this writing) pretty much all electronics have been ordered just printing remaining and coding remain Check out pictures bellow of the dimensional control brackets and the extension wires that have arrived 

Steven Mosbrucker

Steven Mosbrucker

 

64th Week: 3/7/2016

Printed the correct setup of the dimensional control. it turns out that the rollers need to be alot smaller in order for the filament to drop from the nozzle right through the rollers The wire extensions have come in to reach from the dimensional control and spooler to the control box Hall effect sensors and magnets will be ordered soon. dimensional control modules print time is now 100 minutes so i can do 2 and some other prints in the 4 hour blocks of time i am a located. Programming to continue this Friday so that i can print all the final pieces i need to assemble one unit and debug the code. We are getting close to having a unit that prints perfect filament every time. Check out pictures bellow.

Steven Mosbrucker

Steven Mosbrucker

 

Update: 3/2/2017

1st. Techshop has pushed back there close date AGAIN from March 2nd to March 23rd. this has 2 effects. 1 positive 1 negative Got more time to work on setup on cam. However, the negative is that i will not have access to the water jet till the 23rd plus 10 days for them to close and move everything. After pricing out the steel i have found out that buying the pre cut plates of steel is extremely expensive The best option is to buy 4' x 10' giant sheets and cutting out the plates from the sheets on the water jet. that is what i am going to be using in production. and also it is cheaper for prototype Im still contemplating taking some A36 out of my garage and welding the smaller plates into bigger plate and grind the welds flat however i dont think that that will make a very good functional prototype. Im still probably going to do so because i need to get rid of that 1/4 inch steel Now i have a chance to make the template or jig out of plastic so i can instantly home every sheet i put in in order to swap them out quickly. As each machine takes 3.5 sheets I have gotten an estimate for machine time. It came in at 5.5 hours minimum per shredder. my estimate was 2.5 hours. so the price of the shredder if not pre-ordered before first prototype will see a more drastic price increase than originally expected. so in the mean time shopbot out the jig and check the fit on the tormach. and double check the cad file and save the cam for the tormach. and maybe try some A36

Steven Mosbrucker

Steven Mosbrucker

 

62nd Week: 2/21/2017

Was not able to start printing because of more problems with techshops makerbot. because of these continual problems i am going to be looking for my own large format printer began looking at hall effect sensors. and with their cheap price i should be able to implement it into the design as well with a hall effect sensor and magnet combo. wasnt able to upload images of overhang test last week so i will do so this week. check out pictures below.

Steven Mosbrucker

Steven Mosbrucker

 

61st Week: 2/14/17

Bought the wire jumper pins for the load cell board to the arduino Bought the rest of the wire needed for wiring up the rest of the units bought the rest of the bolts needed for the units tested out the overhang print for the dimensional control bracket (picture bellow). Overhangs came out pretty good. not perfect but pretty good. so i should be able to print without supports. however the model still needs a little more manipulation before its done. almost ready to do the software and then test to make sure it works then start building the units one by one to send out. after i build the first dimensional control unit i will be able to assemble one for electronics testing. Check bellow for pictures.

Steven Mosbrucker

Steven Mosbrucker

 

60th Week: 2/7/2016

Finished printing the spooler brackets Starting on the prints for the finished dimensional control brackets. i am going to be trying to print it on the makerbot rep 2 without supports for quicker print times Finishing it up and getting ready for software and starting to put them together to get ready for testing and boxing up buying extended jumper wires and maybe find some hall effect sensors and magnets to glue on the dimensional control rollers to determine the extrusion rate

Steven Mosbrucker

Steven Mosbrucker

 

Ready To Start Prototype

I have taken all the preq steps to get me to the place when i am ready to machine a prototype I have sat in on the classes i need for the Tormach at tech shop and my current (temporary) cam software VCarvePro 8.5 I currently have the prototype shredder nested out in VCarvePro 8.5. ready for 2D routing cam i need to call up my supplier to get some A36 in a 10.5" x 19" x 1/4" plates. and maybe my first 1045 steel 10.5" x 19" x 1/4" plate for first shredder I found out that i will need 3.5 plates of 9.5" x 18" x 1/4" plates per shredder and my estimated time is to be about 130 minutes minimum for machining not including changing plates Because i will find extra expenses in the manufacturing after i manufacture my first prototype i will realize some of these extra expenses and i will increase sale price to reflect that Also when i begin manufacturing the 3 shredders i will also discover the manufacturing the final production of machining and those expenses will also reflect that. So if you have not yet purchased a shredder yet now is the time to do it as this will be the cheapest you will ever find it. after these other 2 points price will increase in according to increase in costs and plugging it into a equation i made so increase cost will not be known tell it is calculated. stay tuned as next update will probably be pictures from the prototype machining process.

Steven Mosbrucker

Steven Mosbrucker

 

59th Week: 1/31/2017

Back into the full swing of school now 3d printing 3-4 times a week now. Still printing the spooler brackets. and only a few more left to go then i need to print the dimension control bracket.  finished assembling the electronic boards i am doing some construction at my parents place so that will cause me to be a little more disorganized Things are moving forward more quickly now that techshop has pushed back their close date and that date should be more stable now

Steven Mosbrucker

Steven Mosbrucker

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