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Hobby Central Phlatprinter II Complete

Discussion in 'Phlatprinter MKII BUILD LOGS' started by billm, Apr 30, 2010.

  1. billm

    billm Member

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    Well I didn't really keep a build log as my build was spread over several weeks with a little construction here and there. The build went relatively smooth. I rushed the paint job as I was thinking of taking it down to our clubs open house tomorrow. I used Rustoleum Hammered Metal spray paint. The problem is you don't get the hammered finish unless you let the spray pool instead of doing the usual thin coats. I haven't calibrated it yet, but all the axis' functions are working. I decided to build the "low cost stand" until I realized the screws, brackets and 2x4's had hit around $100 in Home Depot. That compounded by the fact that I coudln't convince myself to build something else LOL led me to purchase a metal power tool stand from Harbor freight. The stand was $79.99 and I had a 20% off coupon, so I got a multifunction stand for $63.99 that took 15 mins to assemble. I removed the work surface (2 screws) and the Phlatprinter sits on it perfectly and there enough width between the legs for the flex shaft. Eventually I will build two brackets so that I can swing the printer 90 degrees and use the provided material supports. I will post a photo when I get a chance. I have another rising head CNC machine that I use for cutting balsa control line kits and I'm thinking of getting another one of theses stands for it. All in all, it was fun to build. My only gripes is that I feel that the parts list and source list should be included when you purchase the complete package. If you buy a bonz kit for $499 you get it, but if you spend $1100 you don't. After I try it out, I will probably order another Phlatprinter MKII for my other hobby shop. At least that's the official plan - probably more like one at home and one at work LOL.

    Bill
    Hobby Central
     
  2. billm

    billm Member

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    Mark and Trish did a nice job on the intro to Mach 3 and Sketchup. I watched the tutorials and I've ran into my first real snag. I'm at the calibration stage. The foam keeps getting stuck. The drive roller isn't stopping, it keeps going and scuffs the foam. If I push/pull it, it'll continue to track. I sanded down the top to make sure it was not snagging the foam. I think the problem is the large pressure roller. It's not binding, but I had a hard time getting the tape flush. I think the seam is catching the foam and wedging it. I'm going to pull it out tomorrow and strip the tape off of it and start again. Maybe I'll try the spiral wrap. I'm not sure what else it could be. I'm soooo close. LOL.

    Bill
    Hobby Central
     
  3. cncmachineguy

    cncmachineguy Member

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    Ouch, that would drive me insane to be that close. You can confirm the seem is the problem by watching the pressure roller while jogging. If it stops at the seem that's the culprit. The fix is a bit easier then re-wraping. Just trim the offending edge while still on the roller right at the piece under it. Then pick off the little scrap and it should be flush. I think if you pull it all off you will need new tape as I don't think the sticky back will hold up.
     
  4. kram242

    kram242 Administrator Staff Member

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    :D Bill congratulations on completing the Phlatprinter build!! :D
    Sounds like you are right there! If you can't get the calibration to work just give us a call and maybe we can walk through it. I am not understanding why it would get caught.
    One tip for the X roller is to add a drop of CA or Gorilla glue where the small pulley sits on the stepper shaft. They have flat spots on the shaft but over time the pulley tends to want to work loose and it will seem like you are missing steps when really it is a little play caused by the slight movement of the little pulley on the shaft. I test mine by turning the machine on and try to move the drive roller back and forth with my hand if it wiggles you need to get that small pulley locked in place.
    Keep up the good work you are so close!
    Thank you for sharing your experience with us here and happy Phlatprinting!
    :mrgreen:
    Mark and Trish
     
  5. 3DMON

    3DMON Moderator Staff Member

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    I'm not so sure the grip tape would be the issue. Fanfold has waves in it and that could be causing your problems. The waves in the fanfold can grab the surface of the table causing the valley of the wavy foam not to catch the roller. One main fix I would suggest is putting sand, leadshot, or bb's in the top roller to give it some added weight. I bet if you tried a nice flat piece of depron you wouldn't be seeing this issue.
     
  6. billm

    billm Member

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    I gave up at 3am and I'm off to work now LOL. I didn't use the fan-fold, I used a large sheet of 6mm Depron. I will try trimming the seam again, adding weight and glue later today. I'll stop off at Lowes or HD and get some more tape just in case. I also put a piece of balsa through it and it also gets stuck. The X drum doesn't seem to be sticking or skipping - it is spinning and scrapes the bottom of the foam.

    Thanks for everyones Help.
    Bill
    Hobby Central
     
  7. kram242

    kram242 Administrator Staff Member

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    Bill can you post a pic of where it is getting snagged?
    Thank you
    Mark and Trish
     
  8. billm

    billm Member

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    I sure will. I removed the pressure roller and brought it to the store with me. I picked up some non-skid tape on the way in. My wife just removed the filler strip and we' cleaned up the pipe with debonder. I might also try narrow strips of foam and see if it only happens on certain sections of the roller.

    Thanks
    Bill
    Hobby Central
     
  9. 3DMON

    3DMON Moderator Staff Member

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    It sounds almost like the roller is not sitting up high enough from the table.
    If you stick a straight edge across the table over where the roller is how high do you think the roller is protruding up from the table?
     
  10. billm

    billm Member

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    3DMON, we're thinking along the same lines. I just got home and finished checking it out again and figured out the problem is the drive roller. I lifted the cover and placed a piece of 1/4"x4"x36" balsa across the driver roller. I held the lid up, while I moved the balsa back and fort with the keyboard. I placed pressure with my hand on top of the balsa before and after the drive roller. There appaears to be a low spot on the driver roller that is about an inch of the circumference. The drive roller is still spinning, but for about an inch of motion it does not contact the balsa. I powered it off and spun the drive roller back and forth and it does not make contact for the whole 360deg.. I'm not sure what is causing it - thinner outer wall on one section ??? I guess I just need to raise the drive roller up - I'll have to go back an look at how to do it. My wife and I did remove all of the non-skid from the main pressure roller and did a spiral wrap with some new non-skid - looks good anyway LOL.

    Bill
    Hobby Central
     
  11. billm

    billm Member

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    Doesn't look like raising the drive roller is an easy option. :(
     
  12. Evil-Tunes

    Evil-Tunes Moderator Staff Member

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    Just pull out the Drive roller and shim up the bushings :D ..... :?: It rides in the slot I think

    Cheers
    E-T
     
  13. billm

    billm Member

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    I lifted the top panel off and took a look at it. I jogged it and watched the sweeper on the bottom and sure enough the sweeper does not contact all 360 of the roller. I placed the top back on and pounded (don't cringe :twisted: ) the top down. Now it makes enough contact to work - I'll probably have to either replace the drive roller or add something to the surface of the roller to increase the contact. Anyway - I calibrated the X axis several times and it stayed in Cal.. I'm moving on.

    Thanks
    Bill
    Hobby Central
     
  14. billm

    billm Member

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    E-T, I didn't see your post until after I made my last post. I think it is only slotted on the left side. I'll have to go back and take a look to be sure - that would be an easy fix.

    Thanks
    Bill
    Hobby Central
     
  15. 3DMON

    3DMON Moderator Staff Member

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    Without seeing pics or video, it sounds like your describing the roller being out of round.
    But that wouldn't explain the roller not catching at all, so I'm not sure. If it is out of round could the endcap holes be off a little??
    If the roller would need to be shimmed it should be doable. You might have to elongate the hole on the stepper side of the roller to do it though. The main thing is if you do that to make sure you shim both sides the same.
    I would also suggest discussing this issue more with Mark to get his opinion.
     
  16. billm

    billm Member

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    3DMON, it might very be out of round as it does catch except for about an inch. I've calibrated it and checked it several times right now - with no apparent problems. I'm sure its probably not resolved long term - but I'm going to try cutting something for grins.

    Thanks
    Bill
    Hobby Central
     
  17. billm

    billm Member

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    I tried cutting out a test project, but it slipped half way through the cut. I'll have to take another look at the drum tomorrow.

    Bill
    Hobby Central
     
  18. Anonymous

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    Bill, I will guess that you have the feed drum set a bit too low in comparison to the table of the PP. Did you add a layer of something to the tabletop (as I did)? I ask, because my machine would do exactly the same thing occasionally, so I added shims underneath the roller bushings to force the drum up by about 1/16" on both ends. (Doing that was a lot easier than finding a thinner sheet of HDPE lying around in my garage).
     
  19. billm

    billm Member

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    No I didn't add anything, but it may be just too low. I will try shimming it up tomorrow.

    Bill
     
  20. Gefahren

    Gefahren Member

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    Although I don't know if it would stick or not, couldn't you just wrap another layer of Anti-skid tape around the drive roller? or is it to far off on the low spot for that to help?
     
  21. kram242

    kram242 Administrator Staff Member

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    Bill it sounds like you need another drive roller? If that is the case email me and we will send one out to you to get this problem fixed.
    Thank you
    Mark and Trish
     
  22. billm

    billm Member

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    Yeah, I think for whatever reason the roller is out of round and it is just enough to lose sufficient contact to move the material. I thought about adding non-skid to the low area. But, I don't think it would stick and I would think that would mess up the calibration. I just finished removing the drum. Before I removed it, I marked the drum with nail polish where it was slipping.
    After removing the drum, I can see what the problem is. In the area where the drum makes good contact there is no lip on end cap/gears visible - where it slips there is a gap between the lip and the non-skid. It is the same at both ends which would make me think it is a problem with the actual pipe and not the end cap/gears. Mark, I'll email you.

    Thanks
    Bill
    Hobby Central
     
  23. kram242

    kram242 Administrator Staff Member

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    Got it Bill, Thank you we will get a new one out to you ASAP
    Sorry about this delay in your build and thank you for being understanding :oops:
    Mark and Trish
     
  24. billm

    billm Member

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    Mark I'm out for the day and I've been trying to pm u without sucess from my iPhone I will email you tonight as I want to order a bunch of stuff and possibly a phlatformer. Iwill email you in a few hours. I cant wait to play - thanks for your excellent support.

    Bil
     
  25. kram242

    kram242 Administrator Staff Member

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    Sounds good Bill sorry we missed you today. We were baby sitting my sister in laws kids today and took them to the lake :) Thank you for all of your support we look forward to your email.
    Mark and Trish
     

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