balboni design

This is the first proposed assembly with a three-diode core and conical diffusion lens. A partially 3D printed thermal system utilizes the inserts and M3 screws to dissipate heat.

The Core consists of three high-intensity COB LEDs, producing a maximum 1,275 lumens. In theory, Lenses and Cores of varying characteristics can be easily switched out by the user to alter the light as they see fit. For instance: this Core's color temperature is a cool 5000K to offset the clear resin lens that develops a warmer temperature when post-cured with UV light, creating a soothing neutral white. (Pardon the battered LED wafers, these were frequently recycled for multiple prototypes.)

A series of conical lenses that explored refining the resin's surface. SLA 3D printing produces isotropic models, making Formlabs' Clear Resin ideal for uniformly transmitting light. When sufficiently polished, the outer surface produces a wide and bright cast akin to a transparent 75 watt incandescent bulb. (Left to right: only UV post-cure; no post-cure, buffed down to 12,000-grit; and no UV post-curing, buffed down to 12,000-grit, coated with high-gloss acrylic lacquer.)

A PLA prototype of the carriage frame and bracket, with the tool and part cooling fans installed. The part cooling duct is printed with Tough Resin on a Form 2, as it's the only prniter capible of printing hollow parts with fine details.

The final carriage assembly, printed in Onyx nylon with carbon fiber reinforcement fiber. The two e3d hotends can safely achieve +300ºC in under two minutes!

The 'belly of the beast', as it were. The Duet 2 controller uses a wi-fi card and a web-based UI to handle everything from remote control, downloading print jobs, programming and debugging.