1200 x 1200 Large scale DIY 3D printer - Sub33D v3.07

Please check out the Build progress and test print preview video:
https://www.youtube.com/watch?v=eUf5-UCVueU

There is a playlist of full build progress updates and test print videos:
https://www.youtube.com/playlist?list=PLW8e88EbKrS-baD0ZTySmq4-q1nxtejUq

800mm Ledgend of Zelda Master Sword test print:
https://www.youtube.com/watch?v=uNQMUBLKr4Y

T-Rex skull test print:
https://www.youtube.com/watch?v=X6_i6DHRLhA

You can also check us out on Facebook:
https://www.facebook.com/Sub33D/

Filament for the printer is created on our own modified Lyman / Mulier version 5 Filament Extruder:
https://www.youtube.com/watch?v=RwAdB6rVrKg

This printer was designed to print very large scale using recycled ABS plastic (we also recycle, shred and produce recycled ABS filament).
Most of the other very large scale printers out there tend to print in PLA which is a lot less problematic at large scale.

Main features:

• Build volume 1200mm x 1200mm x 600mm
• H bot layout with fixed heat-bed (4 x z-axis motors to move the light weight H frame rather than the insanely heavy heat-bed)
• 1mm nozzle, double volcano extruder hot end to increase flow rate (80W total heater power)
• 2400W heatbed using 4 x 230V 600W 400mm x 400mm silicone heating pads (controlled with 25A solid state relay)
• 2 x Recycled Nema23 stepper motors for y-axis, driven by single 5A TB600 CNC type stepper driver
• 4 x Recycled Nema23 stepper motors for z-axis, driven by single 5A TB600 CNC type stepper driver
• 1 x Recycled Nema23 stepper motor for x-axis, driven by standard DRV8825 2.5A stepper driver
• 1 x Recycled Nema17 stepper motor for extruder, driven by standard DRV8825 2.5A stepper driver
• Modified Ultimaker 1.5.7 PCB main board
• 4 x 150W IR heaters to reduce heat-bed deformation and maintain consistent heat on printed ABS parts.
• Designed in Sketchup Make 2017, design file included in downloads (Sub33D v3.07.09.skp), I have also uploaded Sub33D v3.07.09.stl which is a common intermediate format used by Sketchup and other CAD formats.
• Frame built from 50mm x 50mm x 2mm box section aluminium
• Total build cost is close to $2000 AUD, aproximately add another $500 AUD if your not using recycled components.
• Marlin-RC firmware also included in downloads (Marlin-RC.zip)

If anyone is thinking to build something like this I would recommend using a 12mm heat-bed plate (rather than 6mm) as the aluminium plate deforms up to 5mm when heated to 90 deg C, I am using 9 x 9 point auto-bed leveling to pick up the deformation shape).
Also the 400mm x 400m 600W silicone heaters are a little small as the distance between them causes around a 10 deg C difference on the heat-bed surface between the heaters and above them).

I'm Currently building a new dual 100mm stack extruder with 8 x 40W heater cartridges to allow for a 4 x increase in flow rate over the current design, as the printing speed at this volume is way to slow, once this is done I will share some more of the design details.

There is an image of the wiring (Sub33d_v3.07_stepper_and_heatbed_wiring_diagram_v1.00.zip), which can be used to connect many different 3D printer boards to external CNC type drivers, I used the RAMPS 1.4 in the wiring diagram as this seems to be one of the most common boards.

An old server ATX power supply was used which was around 1000W, although a 500W supply would have been fine.
Only the 12V output was used.
The max current draw is the sum of the following:

• 4 x z-axis Nema23's at 4A total
• 2 x y-axis Nema23's at 4A total
• 1 x x-axis Nema23 at 2A total
• 1 x extruder Nema17 at 1.5A total
• 2 x volcano hotend heaters at 6A total
• several 12V fans, approx 2A total

Which comes to around 19.5A peak at 12V, (please note this does not include the heatbed, which runs off 230V AC mains power at 2400W)

Special thanks to Substation33 for all the support and recycled materials.