Improved Ultimaker 2 Fan Mount

Design files for this project can be found here

One of the often overlooked issued with 3D printing and hot-end design for filament extruders is the cooling mechanism that helps to solidifies the filament after extrusion. Nearly all designs utilize one or two axial fans attached on the sides of the extruder to cool the material after it is extruded. While many of these designs work fairly well, none of these designs are tuned to allow for high print consistencies when fan and print speeds are rapidly changing. Here’s my attempt at designing a fan mount for the Ultimaker 2 that tries to keep the hot-end nozzle’s temperature consistent regardless of changes in the fan or print speeds.

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PIC Based Ultrasound PWM Generator

The code base for this project can be found here

Here’s a fairly simple yet somewhat interesting project that I’ve been working on for the last few days. The idea is to make a simple, configurable ultrasound PWM generator that could be used to drive an electrostatic transducer at low ultrasound frequencies (20 kHz – 200 kHz). To keep parts to a minimum, I used nothing but a PIC12F1840 with a 20 MHz crystal oscillator and a single button for the trigger.

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3D Printed Precision Paste Dispenser

Design files for this project can be found here.
3/16/2015 – Revision C update
6/25/2015 – Download link for my custom software added

Here is a design for a precision paste dispenser that I’ve been working on for the last few months. The goal of this project was to build a solder paste dispenser with a focus on consistent performance, 3D printable design, and minimal use of extraneous parts. While other designs exist (see here, here, here, here, or here), none of the existing designs are capable of low-volume paste dispensing at a consistency required for surface mount parts. These existing implementations are inherently limited by their design: they all use basic pneumatic or belt driven systems that simply don’t offer enough control. Commercial solutions certainly exist (see the Nordson’s EFD series, Fisnar’s PDV-1000 and RV5000DPM, IntelliSpense’s Auger Valve system, Techcon System’s TS7000, and Nordson ASYMTEK Spectrum II) but they usually run well into thousands of dollars ($5k+) for a basic system.

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4:1 Gearbox for NEMA 17 Stepper Motors

Design files for this project can be found here
Parts have been designed to be 0.3mm larger. This should be taken taken into account when printing.

10/6/2014 – Added video

Here is a design for a low-profile (18mm) stackable gearbox that fits onto a standard NEMA 17 stepper motor. The gearing ratio of 4:1 allows for increased torque and positional accuracy from the motor. Herringbone gears are used to provide smooth power transmission from the stepper motor while eliminating the need for thrust bearings. A flat rotating output platform is also provided to allow for easy mounting of attachments.

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Improved Ultimaker 2 Material Extruder

8/26/2015 – Added link to third-party update to design

As I am currently in possession of an Ultimaker 2 from the AMP Lab to create prototypes for yet another project, I’ve had the chance to thoroughly explore amature 3D printing and some of the software associated with modern sub-$3k 3D printers. I’ll leave the software issues for another day, but here I’ll detail a custom extruder design that addresses some major problems with the existing extruder implementations.

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Projects by Kevin