FabScanPi Sandwich Box

This is a alternative box for the FabScanPi (2016 - ) using the latest hardware including raspi 3, raspicam V2 (8MP) and FabScanPi-HAT. You can find all details about the FabScanPi on the http://fabscan.org Website.

This thing is called "sandwich-box" because of the used sandwich material for the box panels.

Instead of the original box which consists of plywood this design is using 2020 standard aluminium profiles in addition with sandwich-material (alu-PET-alu) panels for the box element.

The big advantages of this design are the flexibility which can be used to improve the scanner and to keep up with new components and allows own changes.

You can either use servos or stepper-motors for the laser rotation. The holes in the bottom plate need to be the same as for NEMA17 steppers.

The outer dimensions are about 32 x 32 x 32 cm. The usable space in the inside is about 26 x 26 x 26 cm.

How I Designed This

Bill of material

You'll need the following parts to build your own fabscan sandwich box:

Aluminium profile 2020 type (same as used for MendelMax 1.5)

4x 300mm length (one end with M5 thread)

12x 260mm length

1x 230mm length (both ends with M5 thread)

Sandwich panels (alu-PET-alu) 3mm-type, black color

1x 300mm x 300mm (base)

3x 294mm x 200mm (sidewalls)

1x 180mm x 254mm (front)

1x 294mm x 254mm (top)

~80x screw socket head M5 x 10mm

~80x nuts M5, slider-type for 2020 profiles

4x screw socket head M5 x 20mm

Printed parts:

7x lower corner element

1x lower corner element with raspi-slot

2x upper corner A

2x upper corner B

4x screw hide (printed / painted in black color)

1x flap corner A

1x flap corner B

1x stepper mounting

1x platform holder

2x angle connector (or 4x for less torsion)

1x camera mounting

1x servo mounting R

(1x servo mounting L) when two lasers / servos are in use

1x (or 2x) laser cradle

1x raspberry-pi mounting

optional:

1x handle

4x profile end piece ( http://www.thingiverse.com/thing:248025 )

Working Progress (Blog)

31 May 2016

Box component design finished.

03 Jun 2016

Aluminium profiles, sliding nuts arrived.

04 Jun 2016

First assembly of the profiles. I had to buy M5x12 screws because parts were too thick for M5x10 and too thin for M5x16.

05 - 07 Jun 2016

Design and test print of the stepper holder, angle connector and table holder sucessful.

09 Jun 2016

First version of Laser cradle design and camera mounting finished.

I am still waiting for the ordered black sandwich panels.

10 Jun 2016

Upload of camera mounting and laser cradle. Next will be the servo holder then the raspi mounting. Waiting for specific details about dimensions from Mario.

14 Jun 2016

Design of SG90 servo- and raspi- mounting finished.

I also got the sandwich panels and can start the assembly tomorrow.

16 Jun 2016

Upload of modified flap corner parts as well as the servo mountings and a cap for the M5 screws within the scan-box (to prevent reflextions).

18 Jun 2016

Upload of the raspberry-pi mounting and the appropriate lower corner element.

04 Aug 2016 Hardware is finished, including the new FabScanPi HAT.

08 Jan 2017 Updated Rasberry-Pi holder - removal of SD-Card was improved.

25 Jun 2017 Added a customized holder for the calibration pattern sheet for Software 0.4.0 and beyond.

Category: 3D Printing