To ease fabrication, given the materials and fabrication methods available, the initial CAD model was modified as shown The final version of CAD assembly can be seen in Fig. 1 below.
Fig. 1: Completed CAD assembly
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The driver and driven gears transmitting motion from the motor were also fabricated with FDM. The gears were designed on geargenerator.com and exported to STL format for printing. Dimensions were chosen to amplify the motor's torque output (MA=2.5).
Fabrication of Bearing Shafts
The bearings shafts were cut to size using the jigsaw in the machine shop and then lathed with a file to smooth out the rough cut edges. The shafts sections themselves were, in some instance, not long enough to connect the components they were meant to connect. In such instances, a shaft extender was used to rigidly join two shaft sections.
Baseplate and Stand
The baseplate was laser-cut out of a sheet of acrylic using a sketch of the baseplate surface from the CAD drawing.
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The stand was originally planned to be constructed from 8020 beams, but due to unexpected shipping delays , an alternative had to be found. We choose to use wood legs as an alternative Wooden legs were chosen due to the wood shop having an extra supply of 2x4 available for use.
We cut two Two 3 ft pieces were cut out of an 8ft 2x4 and subsequently cut those to pieces in half, giving us producing 4 legs. Using the jointer and planar machines in the wood we cleaned up shop, the faces of each of the fours four legs was cleaned to achieve a smooth flat surface on each of the faces of the legs. After the facing was completed we cut the legs were cut down to 2 ft while flattening the ends of each of the legs using the table saw.
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