Duet controlled micro mill
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I've been working on this one for a couple months. Using Misumi LX20 actuators with 1mm lead ball screws driven by 1 amp, 1.8 nema 14's on x and y (10 kg of force) and a .9 nema 17 on the Z using 75 mm square, steel bar as the foundation. Tool is driven by a 150K RPM Nakanishi air spindle. The purpose of the build is high accuracy micro machining. I have just ran the first test part, a 9mm diameter sprocket, and it turned out phenomenal (inspecting it with a digital microscope). I plan to try some 3D contouring next and then find the limits in part sized using .5 and .25 mm end mills I have.
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@3DPMicro very cool! Do you have a particular application in mind or just see how small you can go?
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Hey Tony. The selling point for this build, to my wife, was to make custom charms (think Alex and Ani) to peddle but I was mainly thinking of 2nd ops for parts made on my Duet controlled FFF (.1 mm extrusion width squirting PEI and PEKK).
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Username checks out.
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@3dpmicro next you need to build a tiny robot arm to lift the parts from the FFF printer to the micro mill!
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I was able to get the motors to run over 1200 RPM (1200 mm/m travel speed) but while using my test program they stuttered when interpolating corners below a certain radius (G2/G3) with 16x ms, interpolated. Still almost silent and smooth at 8x Ms w/o interpolation. I went all over the place with Accel, and jerk with no apparent effect on the stuttering until down, around 600 mm/m. This 2.3 mm thick part took 14 minutes using a .81 mm end mill including interpolating the 6, 1 mm mounting holes. .1 mm axial DOC and 400 mm/m feed.
The demensions I can measure easily came out within .02 mmp.s. for the record i was not actually using the bathroom when I took the picture
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@3dpmicro said in Duet controlled micro mill:
my Duet controlled FFF (.1 mm extrusion width squirting PEI and PEKK).
I saw your old thread about the probing in a hot chamber.
How is your heated build chamber printer coming along? Can you share some pictures of that? -
@nitrofreak The chamber is working well. 200 - 210c for Ultem 1010. The machine is an IDEX, has a fairly small work envelope of 100 mm cubed and is very stable mechanically and thermally so manual leveling is all that is needed. I would like to post pictures but decided not to until the Stratasys patent has expired. That was supposed to happen this year but could be extended. I am uncertain of the current status.
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My little micro Mill has been working great. No hicups other than the PanelDue touch screen not always working right (too lazy to investigate). I make high precision machined parts at my job using $500k equipment and it still amazes me how accurate and repeatable this $800 machine is. Latest project was a gift I made for my parents 50th wedding anniversary. Using a 20 deg engraving bit with a .1mm tip the machine was consistently able to ablate the thin aluminum film from the backside of the mirror with only minor signs of etching the glass in a few places. This was after surfacing the spoil plate and verifying flatness within .005 mm. This tells me at least the Z is hitting the theoretical .003 mm resolution and doing it pretty darn consistently.
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Pull-pull control horns machined from glass composite sheet on my micro mill. Concept to finished parts in less than an hour
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Triskele charm for my lovely wife. Machined on the Duet Micro Mill of course
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@3DPMicro said in Duet controlled micro mill:
...not to until the Stratasys patent has expired. That was supposed to happen this year but could be extended. I am uncertain of the current status.
You have a great mill, you motivate me to build one too. Very nice!
The patent you mentioned expires Feb 2021 and was discussed in https://www.reddit.com/r/3Dprinting/comments/d1bxy4/did_the_heated_build_chamber_patent_just_get_a/
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JoergS5,
Thanks for the info on the patent.
How big are you going to build your mill? -
@3DPMicro It's in the idea project phase, so no detailed plans yet. But my highest priority will be precision with a small build space (maybe 50 mm in each direction).
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@3DPMicro My special interest would be to mill small parts like
- nozzles like matchless nozzles or SuperVolcano and hotends/heatbreaks for them
- milling tools/cutters for bigger wood or metal CNC spindles
- bigger parts like harmonic drive splines
- producing ball bearing DIY would be nice too (just for fun)
- parts for my Märklin Z trains (they are 1:220 train models)
My general tought is to combine addititive with subtractive manufacturing and make a quality iteration: e.g. 3D print/metal casting/injection molding, then finish by routing/honing/sandblasting. Control product by comparing with the original model and iterate until the goal is reached.
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@JoergS5 it's ,for sure, a good thing we have the Duet along with the work of David and Tony (and whoever else contributes). Now our imaginations aren't so much constrained by money. With the 2 and now the Duet 3 the sky is the limit on functions. Sounds like many of your projects will require turning as well as 4th axis milling. I'm in the process of retrofitting a pretty good-sized manual lathe to CNC using a Duet 2.
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@3DPMicro Would be nice if you create threads about your lathe rebuild here also, as I am sure you have a lot of experience with precision production.
I agree that the Duets are great. I bought them primarily not because of the properties of the board, but because of the good support of firmware and nice, friendly, helpful forum.
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@JoergS5 said in Duet controlled micro mill:
@3DPMicro Would be nice if you create threads about your lathe rebuild here also, as I am sure you have a lot of experience with precision production.
I agree that the Duets are great. I bought them primarily not because of the properties of the board, but because of the good support of firmware and nice, friendly, helpful forum.
I will probably do something similar with the lathe as I have done here with the mill. There doesn't appear to be much in the way of Duet controlled lathes so maybe I will be a bit more thorough with the steps involved. Should be relatively simple since it's only 2 axis but live tooling and/or tool changes will be something I want to incorporate
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@3DPMicro This build looks really great! Is there any chance I could take a peak at a BOM or exploded view? I've been wanting to build something like this for machining watch cases / main plates but I haven't found the time.
Thanks!
-k
