Skeletonized Voron Gantry

I am converting two ender 5s to Tiny M printers. It’s a motion system that I quite like. It’s a V0 voron scaled up to use 2020extrusion. I wanted to get rid of the 2020 extrusion for the gantry and saw an opportunity to make my own skeletonised weight reduced version. I used some cheap 19.05x19.05 tube from Bunnings, modeled it in Onshape and created the pattern.


I somehow messed up my Plunge speeds to be painfully slow so was trying to pre empt movements with the 300% multiplier, and also tried different bits on the cut.
6mm and 3mm.




110Grams saved off the X axis, plus more as I will be screwing the mgn9 rail directly into the aluminium tube so will be using no nuts and shorter m3 screws.

This photo made me reaslise that While my workholding was doing a great job in X axis, I was just pushing it in and the edge wasn’t lining up with the screws. Also if I offset teh screw position from the face that buts up agains the XY joins instead of centering it, I can save a bit of work down the track in modifying the printed parts.


I don’t remember how I messed it up.

But the mature thing was to modify the cad and say that it was a design choice.

The workholding wasn’t exactly sophisticated. But I hope I learned something from it. Will add dog bones next time so that I have a solid reference edge to butt up against.

The finished ish product.



And naturally I side tracked into figuring out how FreeCad does FEA, and got some coloured pictures that aren’t really informing anyting I am doing. But I hope to use it in the future.
I am actually using it to compare torsion table designs. But that’s for another post maybe.

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What an interesting project all around.
I’d love to see more of your TinyM printers, and discussion about how the FEA portion of FreeCAD works (or doesn’t) for you.

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You used a distributed load and fixed it at the ends, that colored picture looks correct. The Hardest part of FEA is knowing how it is connected and the load you are worried about.

The part you made will add some stiffness as indicated by the picture more at the ends then the middle how much actually depends on the rail you are attaching too it. The hard part is knowing if you are adding a piece of spaghetti to an I-beam or adding an I-beam to a piece of Spaghetti.

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This is very interesting and impressive

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Thanks guys. I thought it was different enough from the other stuff I saw in the gallery, so thought I would post.
TinyM was on the radar as a potential group buy in an Australian maker discord, but we ended up doing a massive group buy for Annex Engineering K3 :smiley:
What I always wanted was a printer that wasn’t super specific about which extrusion you used, most stuff is very specific about the width of the channel in your extrusion, and despite infinite cheap options, people seem to end up buying stuff from misumi and importing it. So tiny M seems like it goes on anything. I made one with 20 dollars of steel from Bunnings and it really just goes on anything.


The same motion system bom as the tiny M I got a 180x180 vs a 120x120 build area.

The final push was when I put together a rook and looked at all the parts I was using and realised I could make something with with a much bigger build area with the same parts.
The plates are cut on lowrider too, but I was using some bottom of the barrel endmills, so not showing those cuts off. I keep redesigning the Z. The original design has extrusion that eats a lot into the Y area, so i had to get rid of it. The goal is to have the best footprint to build area, so that slows me down. As a bonus, it has an absolutely beautiful tensioning mechanism on the v5, where you pull the motor in with an M5 bolt and it saves a lot of mess elsewhere.

As far as FEA goes I watched joko engineering videos that in my mind validated freecad as giving solid results as solidworks, so have played with it on occasion, mostly to compare effects on steel thickness on rigidity fo PrintNC and other things. But just for fun. You can get into the flow of freecad if you are using it as the only cad, but it does get tedious. I was using it before I discovered onshape and now its hard to force myself to sit down with freecad. I spent a friday night trying to get results out of it and it was somewhat informative but frustrating. A week later, when I moved on to making my torsion table, i came across this thread.
https://forum.freecad.org/viewtopic.php?t=86698
The attached freecad files are stripped of results and some of the setup. It was incredibly rewarding to be able to replicate their posted results with the workflow from the previous week.
The interface sucks, but I understand all FEM is like that.
I checked out the wiki and the workflow picture kinda makes a lot of sense, but admittedly after I banged my head against my desk a fair amount.
FEM_Workbench_workflow
You get your part, constrain it, load it, mesh it and then solve it. The sub menus for viewing results and specifying which load you are calculating are a little confusing. But once I know where they are I can get the ones (I think ) I want. Also I have a couple of engineer friends in the maker discord, who I show these coloured pictures to. And they usually inform my next step or the reading tangent i descent into.


The triangle pattern is imperfect too. In first image there is one extra one, in the second one the extra is removed, but the spacing is uneven. The two base triangles are spaced with a 2mm distance between the parallel edges, but when I pattern it, I am eyeballing the distance rather than doing the math to get them right. I am hoping to figure out a workflow that allows me to mesh parts from onshape and do FEA on them, because it’s just such a sanity saver. But if I want to progressively test some parametrized designs.
I actually remembered my first play was an attempt to make variable infill based on stresses, where you break down the tiers of stresses and export them as geo and use that geo as a modifier in the slicer to increase infill %. You will have to use your imagination but here is a surfboard with an internal modifier for sparse infill while the outside is denser.

And here is a commercial result that does the same thing.


I think the core on lowrider might benefit from something like this, or even printed ZX plates, Definitely the braces… But I think the setup would be out of my reach for the time being. Though there is a potential to save people some printing time or get more strong for your buck.

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