Académique Documents
Professionnel Documents
Culture Documents
1
CONSTRUCTION MANUAL
By:
Hugh M. Lyman, Jr.
Page 1
CONSTRUCTION COMMENTS
The LYMAN FILAMENT EXTRUDER V4.1 is a complete
assembly for desktop filament extruding. It can extrude 1.75mm
or 3mm diameter filament for desktop 3D Printers. Once setup
it can be left unattended and in about 5 hours it will fill a (1) kg
spool of filament.
Watch the video on YouTube for the setup procedure.
www.youtube.com/watch?v=ofF3eK5Hxk
Figure 1 shows the last Version 4.1. All printed parts are from
filament extruded with Version 4. Figure 2 shows Version 4,
with all printed parts from filament extruded with Version 3.
3mm verse 1.75mm Filament:
If the diameter range of 1.75mm is (+/-) 0.10mm, that is 11.4%
variation.
If the diameter range of 3mm is (+/-) 0.10mm, that is 6.7%
variation.
Therefore, that is why I prefer the 3mm diameter filament.
Also, the 3mm filament extrudes faster than the 1.75mm filament, (not in inches per minute but in pounds per minute).
Page 2
Page 3
Page 4
Page 5
Page 6
Page 7
Page 8
Part 3: Pulley
3D printed. The hole is undersized for dressing to fit the worm gear
shaft.
Part 4: Rubber Band Drive Belt
It is so simple that even I can do it. Simplified Engineering
Part 5: Level Wind Bracket
3D printed. The holes will need dressing for a snug fit of the level
wind sleeve.
Parts 6 & 8: Screws
No Comment
Part 7: Line Guide Pawl
No Comment
Page 9
Sabertooth
Kangaroo
The motors must be tuned and uploaded to the Kangaroo. It has two internal pots one for each motor. The Extruder motor also has an external pot connected to the top terminals on the Kangaroo. I have the M2 (puller motor)
pot removed and an external pot wired in its place for easy M2 motor control. The M1 (extruder motor) internal
pot I have set to full speed. The external M1 pot will override the internal pot used for overall speed control.
Part 3: 24V Rechargeable Battery Pack
This is wired in parallel to the 24V power to the Sabertooth. Why, I dont know so dont ask. I made this one with
19 AAA NIMH rechargeable batteries, only because I had them.
Part 5: External M2 Potentiometer
This is a precession 10 turn 10K pot. It controls the speed of the puller motor to control the diameter of the filament. 1/8 to 1/4 turns makes a difference.
Page 10
Page 11
Again, this is the way I did it, keeping in mind that I use what I
have. There always is a better way. Plug & Play
Page 12
Page 13
Page 14
Page 15
Page 16
Page 17
Page 18
Page 19
Page 20
Page 21
Page 22
Page 23
Page 24
Page 25
Page 26
Page 27
Page 28
Page 29
Page 30
Page 31
Page 32
Page 33
Page 34
Page 35
Page 36
Page 37
BOMLYMANFILAMENTEXTRUDERV4.1(sortedbyDwg#)
TotalEst
Price
Self
Self
QTYestimated
QTYestimated
NOTES:Thesesuppliersareonlysuggestionsandbetterpricing
maybefoundelsewhere
6.00
Extrudedmyown
Extrudedmyown
SUPPLIER
UnitEst
Price
3.29
SUPPLIERPART#
UNIT
$1.50
12.16
QTY
SF
$1.43
$1.43
DESCRIPTION
OZ
OZ
Dwg#
MDFBOARD1/2"12"x46"
8.5
2.3
Part#
A05
ABSFilamentBoxRightSidePanel
ABSFilamentBoxtop
3
A06
A06
ABSFilamentBoxLeftSidePanel
ABSFilamentBoxBottomPanel
ABSFilamentBoxFrontPanel
3.5
8.5
2.3
18
EA
OZ
OZ
OZ
OZ
$0.04
$1.43
$1.43
$1.43
$1.43
0.08
5.01
12.16
3.29
25.74
Extrudedmyown
Extrudedmyown
Extrudedmyown
Extrudedmyown
Self
Self
Self
Self
QTYestimated
QTYestimated
QTYestimated
QTYestimated
Usewhateveryouhave,plywoodetc.
A06
A06
4
A06
ScrewPHSM#6x1/2"
ABSFilamentBoxBackPanel
HomeDepot
A06
A06
A07
A07
A07
A07
A07
A06
A06
AluminumFlange1/2"PipeFlange
NutHexM4NyLok
BlackIronNipple1/2"NPTx4"
BlackPipeCoupling1/2"NPT
BandHeater1"IDx2"long
BrassPlug1/2"NPT
HeatSetInsertsforPlastics
CapScrewM3x6mm
18
18
EA
EA
EA
EA
EA
EA
EA
EA
$13.68
$0.11
$1.28
$2.56
$21.46
$3.69
$0.13
$0.16
1.00
26.38
13.68
0.44
1.28
2.56
21.46
3.69
2.34
2.88
2878A15
44705K228
40147
44615K464
46685K264
G0472516
50785K337
94180A331
11103295
McMasterCarr
McMasterCarr
Fastenal
McMasterCarr
McMasterCarr
ZoroTools
McMasterCarr
McMasterCarr
Fastenal
ODDiametershouldbe1.06"for1"heatband
Needsalittleenlargingbypryingopenatlittle
TrueValueHardware
5
A07
$1.00
$26.38
A07
GearMotorw/Encoder
ABSFilamentHopperMtrMount
EA
OZ
$65.39
$1.43
65.39
11.44
1139507
Extrudedmyown
TD044013
Extrudedmyown
Fastenal
Self
SuperDrollRobotics
Self
QTYestimated
(3)partsA,B,&C.qtyestimated
Usewhateveryouhave,plywoodetc.
Cutto13/4"Sq.Use3/8"thickAlumifavailableasinDwg.
EA
Fastenal
EA
11103318
HomeDepot
1.40
$0.35
0.08
0.30
OakBlock1/2"x13/4"sq.
EA
$0.04
$1.50
AugerBit5/8"X18
SF
A07
EA
A07
CapScrewM4x45mm
0.2
8
A07
ScrewPHSM#6x3/4
MDFBOARD1/2"6"x3"
A07
A07
12
A07
0.56
0.72
TrueValueHardware
11
10
13
$0.28
$1.43
Fastenal
EA
11101213
Fastenal
OZ
0.10
1139518
Fastenal
$0.05
0.40
40353
0.5
EA
$0.20
0.24
ABSFilamentCouplerFlexible
EA
$0.03
McMasterCarr
CapScrewM3x20mm
HexNutM3
EA
6655K16
6338K414
A07
A07
CapScrewM4x14mm
2.60
0.70
A07
14
A07
WasherFlatM4
$2.60
$0.70
14
15
A07
EA
EA
14
16
TrueValueHardware
0.10
BearingThrust7/16"
$0.10
BushingBrassFlanged3/8"ID
EA
A07
A07
WasherFlat7/16"
18
A07
17
19
Page 38
1
EA
EA
UNIT
$1.43
$1.24
$1.24
UnitEst
Price
130.78
8.58
1.24
1.24
TotalEst
Price
11101213
TD044013
tinxiclothes
6391K241
Fastenal
SuperDrollRobotics
eBay
McMasterCarr
9
A08
A08
UrethaneDriveRollers
ABSFilamentIdlerRollerMtBracket
BushingBrassFlanged3/8"ID
3.2
EA
OZ
EA
$27.16
$1.43
$0.70
54.32
4.58
1.40
2475K61
Extrudedmyown
6338K414
TrueValueHardware
Self
McMasterCarr
Self
McMasterCarr
6
A09
A09
LatexTube1/2"ID
WasherFlatM3
ABSFilamentMotorArm
0.6
0.6
OZ
OZ
LOT
EA
OZ
$0.04
$1.43
$1.43
$1.43
$1.00
$0.02
$1.43
0.08
0.86
0.86
0.86
1.00
0.04
0.86
Extrudedmyown
Extrudedmyown
Extrudedmyown
40352
Extrudedmyown
Self
Self
Self
Fastenal
Self
QTYestimated
QTYestimated
QTYestimated
notshownondrawing
This12Vsoneeda220ohmresistorinline
Compressiontype
QTYestimated
QTYestimated
QTYestimated
QTYestimated
NOTES:Thesesuppliersareonlysuggestionsandbetterpricing
maybefoundelsewhere
BOMLYMANFILAMENTEXTRUDERV4.1(sortedbyDwg#)
BushingBrass5/8"ID
1
OZ
$65.39
0.10
SUPPLIER
A07
ThermocoupleTypeK
6
EA
$0.05
Fastenal
Fastenal
SUPPLIERPART#
20
A07
ABSFilamentFunnel
2
EA
40352
QTY
21
A07
GearMotorw/Encoder
2
1139518
DESCRIPTION
22
A08
HexNutM3
0.40
0.04
Dwg#
1
A08
$0.20
$0.02
Part#
EA
Self
EA
Extrudedmyown
McMasterCarr
2
20.02
8920K135
McMasterCarr
$1.43
1.00
8920K135
CapScrewM4x14mm
OZ
$1.00
0.16
1.00
WasherFlatM3
14
EA
$0.04
$1.00
A08
ABSFilamentDriveRollerMtBase
1
EA
EA
A08
A08
ShaftSteel3/8"x3.75"
4
5
A08
ScrewPHSM#6x1/2"
ShaftSteel3/8"x4.5"
A08
A08
10
A08
Extrudedmyown
TrueValueHardware
11
1.50
0.72
Fastenal
$1.50
1139507
eBay
$1.43
0.56
hjb0805
Fastenal
EA
$0.28
10.00
11103297
Fastenal
OZ
EA
$10.00
0.50
40147
Fastenal
Fastenal
1
2
EA
$0.50
0.23
40353
0.5
CapScrewM3x20mm
EA
$0.12
0.44
11103314
Spring1/2"x1"
A08
MiniGearMotor
EA
$0.11
0.18
0.06
ABSFilamentCouplerFlexible
14
A09
Resistor220ohms
EA
$0.18
$0.03
A08
1
A09
ScrewCapM3x10mm
EA
EA
A08
0
A09
NutHexM4NyLok
13
2
A09
CapScrewM4x25mm
WasherFlatM4
12
A09
A09
7
A09
ABSFilamentSpoolHolderLgSide
0.6
EA
OZ
PartsExpress
8
A09
ABSFilamentSpoolHolderSmSide
0.6
QTYestimated
A09
ScrewPHSM#6x1/2"
ABSFilamentSpoolHolderBottom
searchtheinternet
10
A09
A09
TrueValueHardware
12
11
Page 39
BOMLYMANFILAMENTEXTRUDERV4.1(sortedbyDwg#)
EA
UNIT
$1.43
$0.00
UnitEst
Price
5.72
0.33
0.00
TotalEst
Price
Extrudedmyown
Extrudedmyown
Extrudedmyown
Extrudedmyown
Self
Self
Self
Self
QTYestimated
QTYestimated
QTYestimated
QTYestimated
NOTES:Thesesuppliersareonlysuggestionsandbetterpricing
maybefoundelsewhere
1
OZ
$1.43
1.14
4.29
SUPPLIER
0.23
OZ
$1.43
$1.43
SUPPLIERPART#
Shaft6"long
OZ
OZ
QTY
A09
ABSFilamentSpoolCollar2ea
DESCRIPTION
13
A09
ABSFilamentSpoolDiscLg
0.8
Dwg#
14
A09
ABSFilamentMotorShaftCog
ABSFilamentSpoolDiscSm
Part#
15
A09
A09
$Estimated
Usewhatyougot8mm,10mm,3/8"
17
16
EA
Dave'sTackleParts
F092601
WormShaftAssembly
10.00
A10
$10.00
QTYestimated
OZ
0.02
Self
0.12
$0.02
$1.43
Extrudedmyown
ABSFilamentFilamentGuide
EA
OZ
0.17
A10
0.15
A11
A10
ABSFilamentExtruderFanBracket
Fans60mm24V
WormBearing
0.89
0.8
EA
EA
OZ
OZ
EA
EA
$0.11
$0.04
$1.43
$1.43
$3.95
$2.00
0.44
0.16
1.27
1.14
7.90
4.00
Extrudedmyown
Extrudedmyown
17194FN
E144801
Self
Self
Majpa.com
Dave'sTackleParts
QTYestimated
QTYestimated
$Estimated
$1.43
2
ABSFilamentSpoolPulley
3.72
Fastenal
Dave'sTackleParts
QTYestimated
RubberBandBelt
$1.43
0.16
163624
F092601
Self
A10
A10
OZ
$0.04
0.30
2.00
Extrudedmyown
2.6
EA
$0.30
$2.00
0.21
4
ABSFilamentLevelWindBracket
4
EA
EA
QTYestimated
A10
ScrewPHSM#6x1/2"
Self
5
A09
CapScrewM5x15mm
LineGuidePawl
Extrudedmyown
A10
A10
1
A11
ABSFilamentFilamentFanBracket
TrueValueHardware
3
A11
NutHexM4NyLok
ScrewPHSM#6x1/2"
A12
A12
A12
A12
A12
A12
A11
Potentiometers10K
SwitchSPST24VilluminatedBlue
Potentiometers10K
ABSFilamentPotKnob2ea
BatteryPack24V
Kangaroo
Sabertooth2X12
CapScrewM4x25mm
0.32
EA
EA
EA
EA
EA
OZ
EA
EA
EA
EA
$1.75
$1.25
$4.50
$1.00
$0.00
$1.43
$46.89
$49.00
$80.00
$0.18
1.75
2.50
4.50
4.00
0.00
0.46
46.89
49.00
80.00
0.72
31314FU
30184SW
hongkongsuperseller
hongkongsuperseller
Extrudedmyown
TE088220
Kangaroox2
Sabertooth2X12
11103314
40147
MPJA.com
MPJA.com
eBay
eBay
SuperDrollRobotics
Self
SuperDrollRobotics
DimensionEngineering
DimensionEngineering
Fastenal
Ibought2for$8.76
Ibought10for$9.88
QTYestimated
ImadeMyown
OrderthiswiththeexternalM2pot
CheckwithSupplierforadditionalpartsneeded
Fastenal
A12
SwitchSPST110VIlluminatedRed
$Estimated
A11
A11
A12
CircuitBreaker6amp
TrueValueHardware
A12
ThisonecomeswithKangaroo
Page 40
TotalEst
Price
mambate
eBay
NOTES:Thesesuppliersareonlysuggestionsandbetterpricing
maybefoundelsewhere
BOMLYMANFILAMENTEXTRUDERV4.1(sortedbyDwg#)
UnitEst
Price
27.00
SUPPLIER
UNIT
$27.00
SUPPLIERPART#
EA
QTY
DESCRIPTION
PID
Self
eBay
Dwg#
A12
yallstore
Part#
10
Extrudedmyown
QTYestimated
4.29
Priceestimated
18.95
$1.43
AllElectronics.com
$18.95
1.60
PBC46
Fastenal
EA
$0.10
5.00
11103295
OZ
EA
$5.00
1.60
3
16
EA
$0.16
6.00
MaleSpadeConnectorbare
1
EA
$6.00
17.60
ABSFilamentTerminalBd
A12
PCBCopperStrips(4x6)
10
EA
$8.80
PowerSupply24V
13
A12
CapScrewM3x6mm
1
EA
9.00
A11
14
A12
SolidStateRelay
2
EA
$4.50
A12
15
A12
PullUpBoards
1
EA
23.76
12
16
A12
PluginSocket110V
2
$2.64
11
17
A12
HookupKit,notshown
EA
TE179000
SuperDrollRobotics
AllElectronics.com
SuperDrollRobotics
estimated
TE024000
eBay
18
A12
9
25.00
0.00
0
22gahookupwires9colors
$25.00
Itemsnotlistedormissed,connectors,zipties,andetc.
A12
LOT
928.01
84.36
843.64
10%
Contingencies,TTT,Findings
ESTIMATEDFRTIN
SUBTOTALCOST
TOTALCOST
Page 41