A truly massive Voron and DoomCube inspired printer. Designed for 450+ cu mm build volumes, all 6060 HD extrusion frame, Nema23 and 9mm GT3 belts.
To preface the following info, this project is the cumulation of roughly 250+ hours of research and design. No detail was overlooked, and no part too expensive to 3D model (given how many manufacturers provide stl's and f3d files of there parts for this very purpose). The vast majority of this time has been sunk into adapting each and every Voron 2.4 printed part to larger extrusions, wider belts, bigger motors, an inverted design, and on and on...
Due to a ballooning BOM driven by a desire to build a 3D printer that evolves to new tech and stands the test of time, to make certain requirements of the design work was going to require more extensive custom manufacturing; also more than the budget allocated for, increasing the price estimate of various small parts, often needed in multiples of 4, (notably 'D'-profile ended rotary reducing shafts, only 4 needed but huge difference from a straight shaft considering the need for small batch custom lathing) from $7/ea to $100+/ea.
The wheels required (if you want mobility and anti-vibration wheels) for such a robust frame (~92lbs) are $800 for a set of 4. The frame itself is $2000+ assuming you pay Misumi to bore all the access holes and tap the end threads. Keep in mind the 6060 heavy-duty extrusions are expensive. Each column was quoted around $130 (drilled and tapped, adding precision cut is worth it if you have the cash), with the 12 spans running $80+ each. You can save $15-20 on the spans and potentially up to $30 (don't quote me on this) on the columns each, if you choose to drill and tap yourself, if you mess up you eat the cost yourself, its a tough choice.
Add in the price of Nema23 motors, 48V power supplies and 5160pro drivers, GT3 belts, toothed-pulleys, smooth-pulleys, rotary shafts, mic6 build plate, plexiglass, etc, etc, etc.... Soon you look at the BOM and realize you've blown the budget out of the water, ~$4000 was my rough estimate to build this. I will let technology and specifically custom manufacturing overhead to come down a bit, while I focus on finishing school so I can finance this project, and pick up on finishing these designs when the time seems right.
Build the most rigid, structurally sound, and performant large-format 450+ cu mm 3D printer possible, with a focus on modularity and an eye towards the future.
Choose the optimal component at each stage of the design, redesign Voron 2.4 components (ie. build from scratch, using Voron design inspiration) to meet design requirements.
The frame is entirely 6060 Heavy Duty Misumu extrusions (exception is the bed supports which are both 3060).
Provides the torque to overcome the moment inertia of the heavier gantry which is 3030 extrusion, while maintaining the high accelerations over a large build volume that you've come to expect on smaller Voron's.
To run the Nema23's with high efficiency at 48volts. I personally spec the Octopus 5160Pro EZ drivers, avoiding the potential to fry drivers from crossing pins on install.
Provides a 3mm tooth pitch which compared to 2mm pitch belts, provides far greater torque essential for pushing fast accelerations with the Nema23's.
These are incredibly overkill, but the added rigidity, width, and m4 fasteners help it mount more securely on the 6060/3030 extrusions.
Something rarely seen in non-industrial 3D printers, elevated 18 inches off the ground (+3-4" if you use the casters I spec), with a 12" utility cubby (so you have 6" clearance to vacuum underneath) fit for numerous potential uses.
Pre-allocated real estate on the sides and rear of the build-plate provide enough travel room to install various nozzle wipes and the like. The 6060 extrusion allows more of the gantry in the rear especially to be tucked into the rails of the frame. Early experimentation suggests nozzle changes would fit comfortably in this added space (TBD).
6060 extrusion allows more space to fit panels recessed into the machines frame. Thicker panels and/or greater air gaps are possible, maximizing heat retention for your delicate prints.
Say goodbye to artifacts on your large scale prints, the frame is ~92lb before you add the build plate (12+lbs) or any other components. This critical mass is needed to offset the increased vibration with high-accelerations from the Nema23's. I've designed TPU printable shock absorbers designed to work with my Nema23 frame mounts to further amplify this affect.
I could write a small novel about the design decisions faced (despite heavily relying on Voron and DoomCube for inspiration). In the end, the manufacturing sector hasn't specialized in 3D printing enough (for ex. GT3 belts aren't available in open-loop cut-to-length format yet, forcing a revert to GT2 on the gantry which I hope to avoid in production) to make some of there top performance offerings within financial reach of all but the most well-to-do enthusiasts. Stay tuned for more on this topic...