All of the previous prototypes used a controller made from arduino, RAMPS and pololu boards left over from an old 3D printer project It's time for a custom controller PCB. It needs to fit into this space
The PCB design is challenging, but it looks like everything fits
The aluminum enclosure was a bit tricky, but so far everything fits
Almost a full set of parts. Starting to get part numbers and tooling plates organized
Proto 11 is coming together nicely. It shares much of its design with proto 10, with some minor mechanical improvements. Many thanks to Marcel Braun and Matt Gieseler for the insightful observations!
The big improvement is the new custom controller that eliminates the awful wooden box o' crap controller, made from scrounged parts, that was hidden on most previous photos
I'm fortunate to be skilled in PCB (printed circuit board) design, but unlike machined parts, I can't make the board myself, I need to send it out. A small run costs $500-600. When I was employed, and the company paid for it.. no big deal. Today, when I'm paying for it.. gotta be really careful to get it right
Working on wire routing using a dimensionally accurate dummy PCB
Wire routing is hard, especially for things that need to move through large angles in two axes. Wire routing is often ignored by design engineers until right before the deadline. Most CAD systems can't deal with flexible things
I remember many projects where the mechanical guys said "it's done" before my wiring was even started
In the shop
Continuing to work on wire routing
Even though I'm using high-temperature wire (200C, 392F), it must be protected with steel flex conduit
After many hours of frustration and many failed designs, this routing scheme seems to work
The circuit boards arrived, and I assembled the first one. Good thing I have a microscope and SMT soldering skills
All of the parts fit. Tomorrow, I'll start testing
The new custom PCB controller works!
Conduit routing looks good
The PCB wasn't perfect. There were some small problems to work around. The good news is that workarounds were possible. This is not unusual. It usually takes a few revisions to get it perfect
Proto 11 is finished
Now, time to do some glasswork