Phoenix3d
Made by: @codelife / @programmer6
3D Printer Design: CAD & PCB Documentation
Project Status: Awaiting funding
Time 50 HOURS
Repository link: https://github.com/Programer6/Phoenix3D
Why am I making this Printer!
So, why go through the trouble of designing and building a 3D printer from scratch when you can just buy one? For me, this project was never about just getting it made. It was about the challenge and the learning process, more about the 3d printing world since my infill project didn't get approved since I submitted quite late. Highway seemed like the perfect place to apply what I learned about infill by challenging myself by making corexy. After my experience in infill, even tho it was not approved, it actually surprisingly did teach me a lot and challenged me to even make something like this! FUN fact: I will be graded in school on how my 3d printer as it is going to be my personal project!
is this just another corexy :(?
Short answer, not!!
Other than the fact that I put my entire life and soul into designing this, there are some key problems that I noticed, which corexy they are significantly expensive
. After digging a bit online to see how most coreXY are designed, I started to notice a few patterns:
- Why do we even need a separate extrusion for the y linear rails, which can be mounted just using a 3d printed part? huh..,
- Why do we even have 2 linear rails on each side? Well, the answer is stability for sure, but I came to the realization that if you just make the 3d printed part cover more of the space on the bed, it can be just as stable. I saw this on some 3d printers available online.
So those are the key two features that clearly make my 3d printer more accessible to someone who is just getting started, does not have enough budget, or heck, doesn't need a 300*300 printing volume.
Which reminds me, did you know this printer, while still having such a compact form, has almost the capability of printing as much as an ender3?? While most 3d printers in the market use quite a big size in extrusion, they choose a small heat bead so that it is not value for your buck!!!
There is even more. If you look at my 3d printer, you will notice something in the base. There is space to keep the battery, etc., inside, something that makes it more aesthetic than having it outside your printer. Furthermore, even if I have not done it in this version of the 3d printer, I plan to add enclosing (not just for the outside but also for the interior to hide the wires, etc., below)for the 3d printer using the acrylic sheets that are school has in our design lab.
Project Overview
Del-X is a custom‑designed 3D printer, fully OPEN Source.
This build was my deep dive into printer mechanics,and electronics, and is open‑source project you can replicate or remix made for highway.
- Print Volume: 217 × 217 × 230 mm
- Frame: 2020 & 2040 aluminum extrusion
- Motion: CoreXY with linear rails
Just a quick note i was rlly lazy to document the journal while making the 3D printer thus, I don't really remember the excate date of which I completed the making of the 3d printer model thus, I have put the estimate of the time i spent on each of the task! Hope you enjoy going through my journal! |
Here is some research that I did after reviwing AK printer's documentation which came in clutch:
- https://www.instructables.com/How-to-Design-and-Build-a-3D-Printer/
- https://kingroon.com/blogs/3d-print-101/cartesian-vs-corexy
- https://reprap.org/wiki/Build_A_RepRap
- https://www.instructables.com/Complete-newbie-step-by-step-3D-printer-with-all-p/
- https://www.drdflo.com/pages/Guides/How-to-Build-a-3D-Printer/FFF.html
- https://www.geeky-gadgets.com/mondrian-customisable-reprap-3d-printer-07-12-2015/
- https://reprap.org/wiki/Choosing_a_Power_Supply_for_your_RepRap
Overall, it helped me gathering references and brainstorming ideas and I also screenshot various reference images for the guides to help me out later while making my 3d printer. I did really need to do much research but i wanted to keep different compared the the bambu mini style printer that i designed during infill so I went for a CoreXY which is more challenging obviously due the nature of the need of extra extrusion this 3d printer will have to be design at a smaller size of build area of 217 * 217 * 230 mm which is a bit smaller than the bambu mini but it will be more than enough for my needs and I will be able to print at a higher speed and with more precision while also making it compact and later on if I can always add frame which will make it look super cool! This printer is largely inspired by the x301 serise of a open source 3d printer by the marker mashup with a 300300400 build area printer. My design mainly airms to make the over build area smaller and as well as replace the 20*80 which take a significat portion of the bom and are unnecessary.
Build Log
- Then made a BOM:
- 5 hours !!!!!!
- Sourced AliExpress parts: BMG extruder, linear rails, belts. Was extremely hard to stay in budget, hit $300. Some of the part are most like not going to brough such as the neopixels as at this poitn it seems as if i am going quite above my budget of 350$
Bill of Materials
I have not added aliexpress links as they expire or get moved quite quickly as well and the fulctuating nature of the price itself so i hava given a estimate for each section
Phoenix3D (x201) - Full Bill of Materials (Sourced Individually - see cost breakdown in csv)
Frame & Mechanical
| Qty | Item | Notes |
|---|---|---|
| 3 | Aluminum Extrusion 20x80mm | 300mm Long |
| 7 | Aluminum Extrusion 20x20mm | 300mm Long |
| 3 | Aluminum Extrusion 20x20mm | 200mm Long (Cross Members) |
| 2 | Aluminum Extrusion 20x40mm | 300mm Long |
| 1 | Aluminum Sheet .063" thickness | 300mm x 340mm (Bottom Plate) |
| 12 | Aluminum Alloy T Slot L-Shape Joining Plate | Comes with M5x8 Screws & T-Nuts |
| 10 | Inside Connector L-Bracket | For internal frame connections |
| 1 | Gates Powergrip® GT2-6MM Belt | 5 Meters I will have extra) |
| 1 | Bowden Tube | Cut to fit the smaller frame |
| 1 | M10 Fitting | For Bowden tube mount |
Motion System
| Qty | Item | Notes |
|---|---|---|
| 5 | MGN12H Linear Rail | 300mm long, single block |
| 2 | Stainless Steel Lead Screw (T8) | 300mm long, 2mm pitch, 2mm lead |
| 2 | Flexible Shaft Coupling | 5mm to 8mm bore |
| 4 | Nema 17 Stepper Motors (High Torque) | 1.8 degree step angle |
| 1 | Pancake Stepper Motor | For extruder assembly |
| 6 | GT2 Idler Pulley (Toothed) | 5mm Bore, 6mm Width |
| 2 | GT2 Idler Pulley (Toothless/Smooth) | 5mm Bore, 6mm Width |
| 2 | GT2 Pulley (For Steppers) | 20 Teeth, 5mm bore, 6mm Width |
Electronics & Wiring
| Qty | Item | Notes |
|---|---|---|
| 1 | SKR V1.4 Mainboard | |
| 2 | TMC2209 Stepper Driver | For X and Y axes (enables sensorless homing) |
| 2 | TMC2225 Stepper Driver | For Z and Extruder axes |
| 1 | TFT 2.4 Inch Touch Screen Display | |
| 1 | 24v 360w Power Supply | |
| 1 | V6 Style Hot End Nozzle (24v) | |
| 1 | BMG Style Geared Extruder | Right-hand opening version |
| 1 | Ender 3 Style Heat Bed (24v) | ~235mm x 235mm |
| 1 | Stepper Wires (4 Pack) | |
| 1 | 5015 Blower Fan | For part cooling |
| 1 | Mechanical Endstop Limit Switch | For Z-axis homing |
| 1 | USB Mount Panel | For rear of printer |
| 1 | Switched Power Inlet | |
| 1 | JST Connector Kit Assortment | |
| 1 | 1/2" Wire Wrap | For cable management |
| 1 | Shrink Tubing Assortment | |
| 1 | 16 Gauge Silicone Wire | For power connections |
| 1 | Zip Tie Assortment |
3D Printing Materials
| Qty | Item | Notes |
|---|---|---|
| 1 | Pro PLA or PETG Filament | ~1kg, for printing structural & cosmetic parts |
Fasteners & Hardware
| Qty | Item | Notes |
|---|---|---|
| 53 | M5x8mm Socket Head Screw | |
| 56 | M5 T-Nut | |
| 6 | M5x12mm Socket Head Screw | |
| 2 | M5x35 Button Head Screw | For idler towers |
| 4 | M5x40mm Socket Head Screw | For front pulley stacks |
| 5 | M5x20mm Button Head Screw | For display panel |
| 2 | M5 Washer | For rear idler pulleys |
| 68 | M3x8mm Socket Head Screw | |
| 13 | M3x8mm Button Head Screw | |
| 1 | M3x8mm Flat Head Screw | |
| 6 | M3x12mm Socket Head Screws | |
| 4 | M3x40mm Flat Head Screw | For securing the bed to the mounts |
| 34 | M3 T-Nut | |
| 8 | M3 Nut | |
| 8 | M3 Washer | |
| 6 | M4x8mm Button Head Screw | For power supply fan shroud |
| 2 | M4x20mm Socket Head Screw | For part cooling fan |
| 1 | Silicone Leveling Column | Set of 4, replaces bed springs |
End Cost Estimate
Section Lower Estimate (USD) 1. Frame & Mechanical $110 2. Motion System $150 3. Electronics & Wiring $150 4. Fasteners & Hardware $35 Grand Total Estimate $445 - This a high estimate
Optional Upgrades
These parts are not strictly required for a functional printer but are highly recommended for better quality, reliability, and ease of use. I intend to pay for these out of my own pocket in the future.
| Qty | Item | Notes |
|---|---|---|
| 1 | Aluminum Carriage Plate | Rec: Strongly Recommended for rigidity |
| 1 | Dual Sided PEI Build Plate | Opt: ~235mm x 235mm to match the heat bed |
| 1 | Switched Power Inlet (Square Improved Version) | Opt: Provides a cleaner, snap-in installation |
| 1 | Hardened Steel Volcano Nozzles (0.4mm) | Opt: Needed only for printing abrasive filaments |
| 12 | Insulated Fork Spade Wire Connector | Opt: For safer, more secure PSU wiring |
| 3 | Insulated Wire Crimp Terminal (Female) | Opt: For safer, more secure switch wiring |
Build Log
Stage 0: Chossing the equipment MAY 19 - 25
Motion: CoreXY with linear rails for speed and precision.
Extrusion: Bowden setup with a BMG extruder to keep the toolhead light.
Electronics: SKR 1.4 board for 32-bit processing and TMC2209s for sensorless homing.
Stage 1: Base Frame Setup MAY 19 - 25
I modeled the 300x340mm aluminum bottom plate and began assembling the main vertical extrusions (2020 and 2080). This stage was critical for establishing the printer's overall footprint and ensuring the base was perfectly square and rigid. - 5 hour
Stage 2: Top Frame & Z-Axis Motion MAY 26 - 30
I added the top frame extrusions to complete the cube structure. Attention then shifted to the Z-axis. I integrated the 300mm MGN12H linear rails and lead screws, designing the initial printed parts for the bed carriage. - 6 hour
Putting it all together:
Stage 3: Motor & Pulley Mounts JUN 1 - 25
I spent a solid few hours designing and positioning the complex 3D-printed corner mounts for the motors and idler pulleys.
- 15+ hour
- The brackets connecting the build plate to the Z-axis linear rail blocks were custom-designed to perfectly align with the Ender 3-style heat bed's mounting holes.
- Z-axis & XY motor mounts were designed from scratch to precisely align the stepper motors and lead screws with the vertical frame
- Custom feet were designed not just for stability, but also to provide clearance for under-printer electronics and airflow.
Stage 4: Digital Assembly JUN 26- 28
With all the custom parts designed, the final step was the full digital assembly. I put everything together to check for collisions and ensure the mechanics worked.
- 6 hour
Designed the part thoughout the process
Design the BOM - 28
26-28 Since I already had my stuff decided in cad it didn't take that long, about 5 - 6 hours.
Added toolhead
Design the BOM - Jul 8
I was stuck doing a bunch of other YSWS as well as working on other highway projects so it took a bit of a while to actually make the changes after being rejected for not having links in my BOM, missing some electronic component in the BOM, not the changes have been made updated!
Design v2
- 3 hours
added a design update - mainly this is just to give more space at the bottom! for the electronic in terms of z! and also remove the use of 20*40 extension, which should make this 3d printer cheaper to make - by designing a custom holder!
update: - 2 hours
I completely forgot the design tof he heatbead holder & just realized so did that asap & added to the repo! The heatbed that I will be using is going to be 235* 235, heat bed same as the Ender 3.
Design v3 - Aug. 15
+5 Hours
I completely redesigned the toolhead to use less filament and to fit properly with the extruder. Here is how it looks now:
Design v3 - Aug. 26 & 25
+6 Hours
I worked on addressing the feedback I received about my 3D printer design from Tanishq .. The main issue I tackled was the missing part cooler At first, I tried placing the fan duct on the side, but after testing that approach but then realized it would reduce the usable X-axis length so had to redo again. As you can see I am really smart. Other then that i also fix some overlap issues, added the linear rails make and made the part movable & added leadscrew!