Cassini

Background:

My journey into 3D printing began with a challenge: my first printer, a Robo 3D printer broke, and I had to fix it to continue my "customized phone case business". With no background in electronics or hardware, I had to sort it out myself, so I started tinkering around, guided by blog posts and information on open-source sites (all was new to me). This experience was not just about fixing a printer; it was my initiation into the world of hardware and 3D printers.

Cassini Core XY 3D Printer:

I had an ambitious idea: to build my own 3D printers to create customized 3D printers to have "an army" of 3D printers working for me to make new products. Cassini was going to be the first one leading the full development of my project. I started off by making the 3D model on Fusion 360. I simulated my 3D printer in Fusion 360 in various ways to ensure it wouldn't resonate and that each design or bracket wouldn't break. I tested topology optimization parts with different materials, PLA, ABS, PETG, and Ninjaflex, from different brads.
I tested these in the university lab by doing material testing like Tensile, Compression, Hardness, Fatigue and Creep Tests. I was new to materials and polymers, so I had to personally test each brand and material.
So I created the 'Cassini' 3D printer, a machine fully designed on Fusion 360 and built with 3D-printed components. Its structure was entirely 2020 aluminum frame, assembled using zinc brackets, M5 T-slot nuts, and screws. The heart of Cassini's electronics was an Arduino Mega paired with a RAMPS 1.4 shield and 5 NEMA 17 stepper motors. I even designed everything from connectors, extruder, and X and Y carriages.

It took me a long time to understand what it all meant. The printer features were 8mm chromium steel rods on the Y-axis, 10mm carbon fiber rods on the X-axis, and similarly robust components on the Z-axis. The printer was powered by a 360-watt PSU with a 12V output. Its performance handling speed, acceleration, jerk and extrusion were outstanding: I could print up to 300°C on the hot end and 120°C on the heated bed at 150mm/s (very fast).

I did the whole process alone because, as an introverted civil engineer, I knew nobody who liked building products and doing business. All was self-funded from my savings. This is important because people thought I was wasting money by destroying plastics. Still, I saw it as an investment because I was figuring out the best material tailored for my mass-customized 3D printers.

I documented most of this journey on YouTube and shared the software with others for free on GitHub. I was enormously satisfied giving back to the community by giving my design and software for free.I built a printer and contributed to the 3D printing community.

After the printer was printing successfully, I unconsciously upgraded the printer every few months with new algorithms, designs, materials and extruders. I quickly realized that building a 3D printer is a journey without an end. The ever-evolving landscape of technology and the open-source community continually introduce new features, materials, and components. With each advancement, Cassini underwent upgrades, embodying the ongoing commitment to improvement in the world of 3D printing.

My First Hackathon

• . Contextual Introduction:

  • Project Overview: In one sentence, how would you summarize this project?

  • The Problem: What was the core problem or need this project addressed? Why was this problem significant?

  • Objectives: What did you aim to achieve with this project?

My First Hackathon

• Your Contribution:

  • My Role: What was your primary responsibility in this project?

  • Approach & Strategy: How did you plan and structure your work? Did you follow any specific methodologies or frameworks?

  • Challenges Faced: What were the biggest obstacles? How did these challenges shape the project's direction?

My First Hackathon

• The Solution:

  • Key Features: What are the standout features or components of your solution? Why are they important?

  • Technologies & Tools Used: Which tools and technologies were crucial in achieving the project's goals?

  • Design/Development Process: Walk through the main stages of creation. Did you start with sketches, mockups, prototypes?

My First Hackathon

• . Results & Impact:

  • Quantifiable Metrics: What measurable success did the project achieve? Think in terms of user numbers, percentage increases, revenue, etc.

  • Qualitative Outcomes: Beyond numbers, how did the project impact users or the business?

  • Before & After: Can you visually demonstrate the transformation the project brought about?

My First Hackathon

• 8. Learnings & Reflections:

  • What You Learned: Were there new skills or insights you gained from this project?

  • What You'd Do Differently: Looking back, are there aspects you'd change or approaches you'd reconsider?

My First Hackathon

• 9. Additional Resources:

  • Links: Are there external resources or full case studies that provide deeper insights?

  • Downloads: Do you have supplementary materials that someone might find valuable?

  • Related Projects: Which of your other projects might be of interest to someone who found this one compelling?