Our favorite byproduct of kit building … sparks!

Before there was a Nova Labs there existed an ache, a yearning in the hearts of several eventual-founders to build a 3D printer. Undertaking the effort individually was likely to result in frustration over a long period of angst and eventual abandonment of the project. That was the outcome we could foresee of going it alone; that was result we wanted to plan to avoid.

For a variety of reasons we decided that the answer was to build printers with others. As believers in makerspace values we knew that a collaborative and supportive community would help guard against failure. Furthermore, by choosing an open hardware design we could get lots of help from the extended community and that by synchronizing our buying we could reduce costs. Also, by getting into a rhythm of regular meetings we could push each other forward toward the finish line and make friends in the process. In theory, a win all around.

Build group #1 was a rag tag effort which predated but continued within Nova Labs. As interest swelled in both 3D printers and in our makerspace, enthusiasm grew in starting another class so build group #2 was started. The second effort was particularly useful in bringing discipline to the process. Since then enthusiasm hasn’t ebbed. These efforts have proven to be beneficial for all concerned. More than 20 printers have been started and are in various stages of completion. Time for build group #3? Apparently! 

The core idea of the RepRap 3D printer initiative is that people should be able to cheaply build their own printers using plastic parts made from other 3D printers and buying parts that are readily sourced (nuts, bolts, rods, etc.). As an established group we have working printers which we can tap to produce “plastics” for new build groups. As an established group we have the sourcing experience, the process discipline and building knowhow to crank start the build group machinery and move another class through the process. After a new group is formed, the next steps are buying supplies and building kits.

Tonight was all about building kits from purchased parts and printed plastics.

The evening started with getting organized for the big production.

A big job is cutting meter-long rods for the Prusa’s structure which requires a mix of threaded and smooth rods of precise lengths. Here Nikolai uses the chop saw, the first step in preparing the rods.

There are lots of rods needed for this build group so cutting extended into the night.

After cutting, the ends of the rods need to be ground smooth.

There was lots of related activity in the kit-building process and it involved many people. When the job proved to be bigger than the space, we moved outside.

The goal is to build kit bags with plastics, “vitamins” and stepper motors. Here you can see an assemblage which include the printed plastic parts, some of the smaller “vitamins” (bolts, nuts, etc.) and the very-important stepper motors. Along with the rods you have stage one parts to assemble the mechanical aspects of the Prusa; stage two brings in the electronics.

Toward the end of the evening with the job is almost done it was time to ease back and enjoy the fruits of the evening’s labor . (Note that the rods have been added to the build kit bags.)