Lets see if I can comment on all of the responses. Lots of fun pics attached, and links embedded.
History of my setup. This is my first 3D printer, and I jumped into the deep end by starting with a Delta. I knew this was going to be a challenge, before I started. After 20 years of building CNC routers, I do have a rather solid understanding of most the concepts. I tried to buy, what I though was, best in class hardware. I loosely designed my Delta off the Kossel concept. Please keep in mind I started this build in May of 2019 and I am still learning a LOT, so take everything I have to say with a grain of salt.
Extruder(s) and what led to condoms..... I started off with the nimble extruder, and my effector was nothing more than a simple CNC'ed plate (Version 1). This got me through MANY of the early learning pains. The counterfeit stepper controllers (Leadshine DM556
's) were the hardest to troubleshoot. Although the uStepperS
closed loop steppers missing steppes had some of the most fun out comes. At one point I was even running all motion control off an Arduino Uno! But I always had problem with ghosting
at high speeds (+250mm/s).
My goal is to reach a print speed of 1000mm/s. As my delta matured, so did my effectors, but I was never able to locate the root cause of a minor fluctuation/ripple in the print surface. It was not ghosting, it was something else. Said fluctuation/ripple were on all of my parts and was there from the beginning of my machine. So on a whim, I strapped a BMG extruder onto my effector (V3). First time in all this time I had a flawless finish quality. The only change was Nimble to BMG. So I built V4 of my effector which had native BMG
support. Instant ghosting, even at slow speeds!
Turns out when you add a ton of weight to the effector, you get lots of ghosting. This lead me to new/bigger belts. I upgraded from GT2 to HTD3M
belts, and solved the ghosting, at slower speeds. I knew weight on the effector was a BAD thing. I proved that the Nimble was causing some kind of strange issues. So this lead to removing the nimble drive cable and direct attaching a NEMA 8 motor (V5). The results were perfect, kinda. The 1/4~1/2 of a 3DBenchy was perfect, but the motor would over heat, and freeze up. Even a bigger NEMA8 suffered the same issues. But I had hope.
I found a cool worm drive extruder on thingiverse
which I quickly adapted to a NEMA 11 motor (V6). The NEMA11 did not overheat, but still ran too hot for my tastes. The worm drive also had a gear engagement issue that was again causing surface defects. To make matters worse, I still had a big heavy motor on the effector. Then I saw my first picture of a flying extruder. I was able to quickly print out a test of the concept, and fell in love!
My goals with the flying extruder concept. Remove ALL weight from the effector. Even better if I can remove any other extra forces, like the constant push of the Nimbles drive cable. Thus leading to my current setup.
The Nimble. I love the concept, but I think the drive cable is having issues. But I don't understand exactly what. I have seen other complaints about this on-line.
The BMG. I love everything about it, except the weight.
The NEMA 8's all had overheating problems, in my setup. Please keep in mind I run my motors at 36V.
NEMA 11 + worm drive works, but I was having gear problems, and heat issues.
Now to tackle the current state. The condoms will degrade fast. It's just going to happen with any natural rubber product. I have pondered some of the non-latex condoms. I have found that ultrasound probe covers
might be a good non-latex option. But non-latex condoms are much simpler to come by. I have also pondered using something like rip-stop nylon fabric. It has no elasticity, so would require a longer length, thus prone to more kinking. I am not sure what the best path/option is, yet.
Water cooling has always been on my radar. But I never found a small water cooled heat block. Many of the solution just put a jacket around the E3D V6 heat sink, which is kinda pointless. Daren, what are you using? Links/pictures?
Please ask questions, or comments. I am always looking for ways to improve.