VULCAN 3D PRINTER

Challenge: The Previous Prusa Titan build suffered from a heavy moving bed, causing quality issues and speed limitations.

Solution: Implemented a modern CoreXY motion system where:

• Bed moves only vertically (Z-axis)

• Gantry controls X-Y motion

• Lightweight print head design via remote motor mounting

Key Design Decision: Initially planned a single Y-axis motor but switched to a belt-synchronized dual rail system to prevent misalignment at high speeds—maintaining single-motor simplicity while ensuring balanced movement.

Applied design principles from humanoid robot development to create structurally optimized 3D-printed components:

Extruder Block:

• Integrated dual print head mounts

• Internal cable routing channels

• Bearing housings for smooth linear motion

• BLTouch sensor mount

• Material cost: ~$5 vs $200+ for machined equivalent

Corner Brackets:

• Single-piece construction housing X and Y linear rods

• Integrated bearing mounts

• Optimized infill patterns for high-stress areas

• Design informed by robotics research on 3D-printed structural components

Total AM parts cost: ~$40 in filament vs $1,000+ for machined components

Design Process:

• Complete CAD model in Siemens NX before purchasing hardware

• Motion simulation and clearance checking

• Iterative refinement based on research and community builds

• Bill of materials optimization for budget constraints

Assembly Insights:

• Mechanical assembly: 2 days (accelerated by detailed CAD pre-planning)

• Electrical integration: In progress when discontinued

• Main challenge: Z-axis ball screw alignment (solved through careful leveling)

What Worked:

• Thorough CAD modeling prevented costly mistakes

• AM structural components performed well while reducing costs 80%

• Belt-synchronized Y-axis solved single-motor limitations

• Remote motor mounting significantly reduced moving mass

What Didn't Work:

• Using 4 linear rods for the z-axis in each corner

• Trying to keep the electronics separate from the printer

• Using 45 x 45 mm extruded aluminum

Project Outcome: Discontinued to focus on PhD research. The existing Ender 3 provided sufficient capability for personal needs while I completed my research.