3D Printer Design: CAD & PCB Documentation

Made by: @codelife / @programmer6

Project Status	Awaiting funding
Total Time	60+ HOURS
CAD Link	https://a360.co/3TjGkbB
Repository	https://github.com/Programer6/Delta-Forge/

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Frame Build June 26- July 3

Time: 2 Hours

I kicked things off with the core structure of the printer. Since it's a delta, getting the geometry right from the start was super important. First, I designed the main triangular frame using 2020 aluminum extrusions. This forms the three vertical towers and the triangular base and top sections & makes sure all of the extrusions were in the correct 60-degree angles.

• Assembled triangle frame using 2020

Bottom Build Plate

Time: 3 Hours

At the same time, I designed the bottom build plate. I went with a hexagonal shape, which matched Delta's geometry & was inspired by the Delta Flyer keep the footprint small and stable. You can see the CAD screenshot where I sketched out the 120mm circular build area to make sure the hotend would have full access and everything would be centered correctly.

Assembled Together July 4 -5

Corner Support (3 Extrusions Holder) Jul 6 - 14

Time: 7-8+ Hours

Attempt one, one making this completely failed as you can see in the picture as this one part needs ot connect to two of the bottom extrusions + the same time provide support to the top extrusion! + have the write spacing in between for allowing the belt controled by the nema 17 motors below!! So measurement not only needed to be precise, considering this is an important part! WHICH I COMPLETELY FAILED DOING IN THE FIRST ATTEMPT! :(

Attempt 1 (Almost 2 hours wasted)

Attempt 2

Measurement goes crazy as you can see while juggling multiple things, but worth it:

How it looks after extruded:

Part 1: Top Bracket

This was the first version of the extrusion holder designed for the top part of the 3D printer.

Part 2: Bottom Bracket

This was the second version of the extrusion holder the same, but the difference being that it allows the nema 17 extrusion to be srewed in the bottom.

Assembling

Time: 3 Hours

• Adding the extrusion to its correct places!!
• Bottom & top extrusion holder images:

Grill Design Jul 15

Time: 2 Hours

Since I got one of the most important and time consuming part of the 3d Printer done I moved on to the making of a grill design to put at the buttom part of my 3D printer by screwing it together to the extrusions this is mainly for design purpose to make the 3d pritner to look overally more pretty and to hind the Nema 17 stepper motors which are hiding at the bottom of the 3d printer. Since this required a bunch of boxes & stuff, this was time-consuming to make!

Spool Jul 16

Time: 3 Hours

Since I don't really own a 3D printer (yet) this means that I don't have a spool holder. Instead of just buying one from Aliexpress, I thought that it would be a really cool idea if I went and designed one myself:

Electronics Holder Jul 17-18

Time: 5 Hours

A simple box-style extrusion holder for the top part of the 3D printer. This took a lot of time to make for optimizing the perfect fit, for example, making sure it does not touch the / overlap with other parts + also adding a place to keep the electronics.

Delta Arms Jul 18

Time: 30 Mins

Nothing crazy, download the join for the internet and made the main body of the Delta Arm in the size that I needed!

Extrusion Cover Jul 19

Time: 3.5 Hours

Cool design, simple design to hide the Z axis extrusion with the 3D printed part & to hopefully use to add clear acrylic (as a later upgrade) to cover it to make it look overall polished!

Putting It All Together + Adding Color Jul 19

Time: 5 Hours

Pretty self-explanatory.

Documentation & Sourcing

Time: 5 Hours

Sourcing part making the bom, finding the parts on Aliexpress, writing the journal & the readme which you are reading right now!!

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Final Renderings

• Assembly Animation

https://github.com/user-attachments/assets/61bd661a-ea38-4a6c-9b39-ed1613a4cac2

• Turntable View

https://github.com/user-attachments/assets/fd6eddad-ef06-40b8-ad82-d1f1cbdf5e5e

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Hoped you liked reviewing my project!