FLSun Delta
Due to a warehouse mishap, this was my very first printer, which I assembled and tuned with the goal of being able to print my own designs. Building this machine gave me exposure to the uncommon Delta-style printer configuration, whose lightweight printhead allows for creating accurate models at higher speeds than other machines. After a year of use, this printer was sold to a colleague in order to clear space for higher-budget machines.
= Upgrades =
External MOSFET Bed Relay
The low-cost design of the Delta meant that some corners were cut in the design of its electronics. The heated bed draws a substantial amount of power, and the original design configuration had this current running directly through the mainboard. This is a poor setup, as the circuitry is not equipped to handle such large current draw, which presents a fire hazard and puts the mainboard at risk of premature failure. To circumvent these concerns, an external MOSFET board was installed, acting as a switch that the mainboard could remotely enable to direct current to the heated bed.
Customized Marlin 2.0 Firmware
The original firmware made the printer a fire hazard, as it had no failsafe to account for thermal runaway. As such, any failure in thermometer wiring that caused an erroneously low temperature reading would result in a positive feedback loop, with the printer pumping in heat to a system that is already sufficiently hot. This may continue until the system fails or begins to melt, with potentially disastrous results. To remove this concern, the printer was upgraded to the Marlin 2.0 firmware with thermal runaway protection, improved user interface, and more. This firmware was then tweaked and customized to adjust various parameters of the user interface and printer behaviour.
Borosilicate Glass Bed
This printer originally came with no build surface, requiring the application of painter's tape in order to obtain any kind of successful print on the heated bed. However, this produced an uneven, ugly print surface, with fibers from the tape frequently embedding themselves in the printed part. Additionally, the use of painter's tape required frequent maintenance and reapplication. For improved print quality and ease of use, a plate of borosilicate glass was installed, with its strength and resistance to thermal shock making it a solid choice of build surface.
Top-Mounted Filament Stand
The Delta came with no filament holder of any kind, which was highly inconvenient as the filament has no location from which it could freely unspool throughout the course of a print. To remedy this, a top-mounted filament holder was designed in SolidWorks and 3D-printed. This spool holder includes interchangeable fittings for different spool sizes, and allows filament to be smoothly pulled off the roll by the extruder motor throughout a print.
High-Flow Silent Cooling & PID Tuning
The original fans on the Delta were of sub-optimal quality, resulting in noisy operation and premature failure. For improved cooling and reduced noise pollution, all printhead and control board fans were replaced with silent Noctua A4x20 fans. These fans provide significantly improved airflow and reliability while simultaneously being nearly inaudible during operation. Following this upgrade, the hotend was PID turned to optimize temperature regulation.
Vibration Damping
This printer, while provided with a strong aluminum extrusion frame, was not as sturdy as it could be, and the fast-moving x and y-axis stepper motors mounted on the frame produce substantial vibration. This results in resonance through the frame and its components, producing a buzz or whine as the printhead travels. Printed parts also suffer as a result, often experiencing a "ghosting" effect along outer faces due to the vibration in the frame. To remedy this, motor dampers were installed on both steppers, all fan mounts were damped with rubber washers, and the base of the printer was cushioned with a foam bed. As a result, the printer was rendered effectively silent, an impressive feat for a budget 3D printer.