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This is important step forward for the entire field: open source sub 1500 USD metal printer. It can be mad by anyone with some experience. It is based on static MIG welder and moving invert delta 3d printer platform as build bed.

Project was developed by Michigan Tech's Open Sustainability Technology Lab: Gerald C. Anzalone, Chenlong Zhang, Bas Wijnen, Paul G. Sanders and Joshua M. Pearce. Kudos to you gentlemen!


From project abstract:

Technical progress in the open-source self replicating rapid prototyper (RepRap) community has enabled a distributed form of additive manufacturing to expand rapidly using polymer-based materials. However, the lack of an open-source metal alternative and the high capital costs and slow throughput of proprietary commercialized metal 3-D printers has severely restricted their deployment. The applications of commercialized metal 3-D printers are limited to only rapid prototyping and expensive finished products. This severely restricts the access of the technology for small and medium enterprises, the developing world and for use in laboratories. This paper reports on the development of a <$2000 open-source metal 3-D printer. The metal 3-D printer is controlled with an open-source micro-controller and is a combination of a low-cost commercial gas-metal arc welder and a derivative of the Rostock, a deltabot RepRap. The bill of materials, electrical and mechanical design schematics, and basic construction and operating procedures are provided. A preliminary technical analysis of the properties of the 3-D printer and the resultant steel products are performed. The results of printing customized functional metal parts are discussed and conclusions are drawn about the potential for the technology and the future work necessary for the mass distribution of this technology.

Project homepage with detailed build instructions:

http://www.appropedia.org/Open-source_metal_3-D_printer

Academia paper on this printer:

https://www.academia.edu/5327317/A_Low-Cost_Open-Source_Metal_3-D_Printer

If you want to learn more about MIG (metal inert gas) welding:

http://en.wikipedia.org/wiki/Gas_metal_arc_welding

















































There is another welder based DIY metal 3d printer project with almost no documentation - The Chipfuzer:

http://diy3dprinting.blogspot.com/2013/11/chipfuzer-diy-3d-metal-printer-by-mark.html

Another delta Kickstarter. BI v2.0 comes with some powerful features and affordable price.

From Kickstarter description:

The BI V2.0 capably produces very large 300 mm diameter X 300 mm height prints and features an amazing print quality (Be sure to read more about the definition of a true delta build volume below). Our design can support up to triple extrusion and can print virtually any 1.75 mm filament extruding at up to 240 degrees Celsius (PLA/ABS/Nylon etc.). The most unique aspect of the BI V2.0 is our innovative approach towards a self-replicating design which permits the simple creation of extremely precise movement. The end result: the highest standards of print quality. The self-replicating design of the BI V2.0 empowers you to create your own machine and share this technology with your family and friends. Once you receive the BI V2.0, you can print, improve upon and share components so that anyone can build their own printer at a very low cost.

http://www.kickstarter.com/projects/1784037324/bi-v20-a-self-replicating-high-precision-3d-printe

http://bootsindustries.com/shop/biv2/

Comparison table of BI v 2.0 vs. Deltaprintr whereby BI wins

BI v2.0 print results

Electromagnetic automatic leveling probe is standard in every unit

From Kickstarter page:

Rather than mechanical endstops the RappiDelta Jr. utilises slotted optical sensors which prove more repeatable homing and ultimately better prints. One of my stretch goals is to be able to offer auto bed leveling to further enhance the functionality and ease of use.
The remainder of the mechanical parts can be assembled quickly and easily with a couple of hex keys.
Once assembled the printer can print on a 17cm diameter circle and up to 17cm tall. These dimensions have been chosen based on my experience of what is actually reasonable to print as well as being based on a similar size to other entry level printers. In future you can increase the build volume by using longer uprights, and if required longer delta arms. The basic model has no bed heater and as such is limited to printing PLA (this is actually my preferred plastic!) but other options are available to allow the printing of ABS and other plastics that need bed heating. There is also an option to have an SD Card reader and LCD control panel to allow printing without a PC, something that I have found invaluable when developing my prints as it allows on the fly adjustments.

This delta projects wants to deliver cheap simple printer, with few easily assembled printable frame parts.




Junior has a bigger parent:

http://diy3dprinting.blogspot.com/2014/01/rappidelta-large-print-area-delta-3d.html

Company page:

http://www.rappidelta.com/

Junior had a (canceled) Kickstarter:

http://www.kickstarter.com/projects/1734895403/rappidelta-jr-ultra-low-price-3d-printer-for-every

Every day I find more deltas. Here is Rappidelta by David Akers, large volume aluminum frame delta 3d printer which can print in printvolume up to 40cm X 40cm X 40cm.




Rappidelta can also 3d scan objects:




Company page:

http://www.rappidelta.com/

Rappidelta Kickstarter campaign page:

http://www.kickstarter.com/projects/1734895403/rappidelta-large-format-delta-3d-printer-join-the




Rappidelta has a smaller, simpler version:

http://diy3dprinting.blogspot.com/2014/01/rappidelta-jr-low-cost-simple-delta-3d.html

Kossel design and Mini Kosseel are often around, for some reason I forgot to make a post about it. So here it is ...




Design Goals from the Kossel page:

• Zero backlash.
• type: Delta printer
• Speed: 320 mm/s in all 3 directions.
• Resolution: 100 steps/mm in all 3 directions.
• Repeatability: better than 0.03 mm (30 micron)
• Build volume: cylindrical, 170mm diameter, 240mm height.
• Footprint: triangle, 300 mm width (240mm OpenBeam + printed corners).
• Frame height: 600 mm.
• Print surface: unheated round glass, doesn't move.
• Mass of end effector with hotend: less than 50 grams.
• Simplicity: fewer than 200 parts.
• Hardware cost: less than $600 USD.
• Fully automatic print surface level calibration (autoleveling).

https://github.com/jcrocholl/kossel

http://reprap.org/wiki/Kossel

http://deltabot.tumblr.com/

Build manual:

http://www.builda3dprinter.eu/build-manuals/kossel_mini/

Here is the demonstration of the autolevel feature:

http://diy3dprinting.blogspot.com/2013/05/automatic-bed-leveling-on-mini-kossel.html
http://diy3dprinting.blogspot.com/2013/06/mini-kossel-prints-on-unheated-glass.html

Another Rostock derived Delta 3d printer with very detailed build guide.

From project page:

The MOST Delta printer is RepRap derived from the Rostock printer with the following design goals:

• Simple build process
• Safe to operate
• True to RepRap
• Maximize value
• Maximize rigidity
• Aesthetically pleasing (or at least neutral)
• All PLA printed parts
• Excellent print performance

The design utilizes plywood linking boards cut to a length that yields a desired printer radius when attached to the printed apexes. This simplifies assembly while helping to assure that printer dimensions are fixed, stable and reasonably well known. It also improves flexibility as the print area in the x-y plane can be changed simply by replacing the boards with boards of a different length. The delta design is inherently simpler to assemble as compared to virtually all it's Cartesian counterparts; this design can easily be built within a day by one person having properly prepared parts.
The design uses a 12v 5A power brick instead of the popular 12v power supplies having mains connections relatively exposed, a relative safety issue, particularly when children are present. The power supply is roughly equivalent to those found with many inkjet printers.
As many printed parts are used in the design as are practical, including printed pulleys. This in large part drove the decision to use open T5 timing belts for the drive, which also makes the design more flexible as the length of the guide rods doesn't need to be based upon the length of an off-the-shelf continuous belt.
Cost considerations drove decisions regarding everything from printer capabilities (as shown, prints PLA only) to guide rod material and length (two six foot lengths of 8mm drill steel are required, producing no waste). A Melzi controller is used as it provides all the necessary features as well as SD card support and reasonable expansion options. The power supply is a fraction of the cost of that required for powering a heated bed.
Printed apexes are very robust, probably overkill, and along with the plywood components and ample fasteners produce a very rigid structure. The printer has proven to transport very well (and can even be seat belted) with no adjustment needed prior to printing at its destination.
The end effector is actively cooled allowing for a unitized effector/hot end mount printed in PLA. The hot end is recessed within the end effector, maximizing z-axis travel and also providing for some print cooling.
Printing performance has been very good as has been the experience of printing with this design. Much less user intervention has been required as compared to experience with Cartesian RepRaps.

Printer capabilities/statistics

• Print media: PLA only (heated bed can be added, expanding media options)
• Filament diameter: 1.75mm
• Nozzle diameter: 0.5mm (can be changed)
• Print volume: ~250mm radius (with 240mm long linking boards) 270mm high
• Melzi print controller w/ integrated SD card reader
• Airtripper's Bowden Extruder

Appropedia page with very detailed build guide:

http://www.appropedia.org/Delta_Build_Overview:MOST

Github file repository:

https://github.com/mtu-most/most-delta


Appropedia is very interesting wiki with many detailed open source DIY projects woth looking at.

Appropedia is the site for collaborative solutions in sustainability, poverty reduction and international development through the use of sound principles and appropriate technology and the sharing of wisdom and project information.

http://diy3dprinting.blogspot.com/2013/12/delta4-printer-with-four-delta-printers.html


MOST is Pearce Research Group at Michigan Tech in Open Sustainability Technology.
They have many cool stuff here: http://www.appropedia.org/MOST

Turi Cacciatore made this Rostock based custom Delta 3d printer with frame made from Ikea furniture pieces. He used carbon archery arrows for delta arms. Nice work!



Source with detailed information and building guide:

http://turicacciatore.tumblr.com/post/69085105229/making-my-3d-printer

Custom Delta frame made from cut Ikea pieces pictured above

You can see another 3d printer from hacked Ikea furniture pieces, the Ikea RepRap, here:

http://diy3dprinting.blogspot.com/2013/11/diy-3d-printers-made-from-wood.html 

DeltaTrix is open source delta configuration 3d printer project by Richard Tegelbeckers. It has very detailed Instructables building guide and features sturdy cnc cut wood frame with Airtripper Bowden Extruder, RepRapPro Tricolour hot end and RAMPS electronics. He will also Kickstarter it soon.




Detailed construction manual and all the files needed:

http://www.instructables.com/id/DeltaTrix-3D-Printer/?ALLSTEPS

DeltaTrix has sturdy CNC cut full wood frame construction

DeltaTrix print results

There are some similar detailed build guides for Delta printers like this one if you are interested in building different model:

http://diy3dprinting.blogspot.com/2013/09/extensive-roctock-delta-building.html

Update:

It is on Kickstarter now:

http://www.kickstarter.com/projects/1142241325/deltatrix-3d-printer-open-source-and-fully-hackabl


Technical specifications described in Kickstarter campaign:

The theoretical printing area is 280mm (11 inch) in diameter. As a square this works out as (almost) 200x200mm (8"x8"), which suits the used 'MK2A' heated bed. As it is also useful to be able to remove items, the gap between the uprights is just over 295mm. The maximum build height is around 280mm (11").
Main features:

• Linear delta robot layout provides a mechanically simple motion platform for moving the print head only, not the workpiece.

• Off the shelf RAMPS electronics allow for easy replacement in case things go wrong.

• Using a LCD display and SD memory card (supplied in our kits), the DeltaTrix 3D Printer can operate on it's own. It does not need to be attached to a computer.

• There are several (Open Source) options in terms of software. At the moment we are using Repetier on the PC, a modified version of Marlin as the firmware on the RAMPS electronics, and the standard Arduino IDE for tweaking the firmware.

• A heated bed with glass print surface, allows for PLA and ABS to be used as filament.

• In terms of filament, the DeltaTrix 3D Printer is designed to accept 1.75mm PLA and ABS on a variety of 1kg reels, as long as it is of good quality.

• Igus linear slides with pretension are used, providing a robust and durable bearing solution from a highly reputable manufacturer. The strengthening ribs on the uprights keep the rails straight and sturdy.

• The current design print head assembly uses a single Reprappro Hot End, with a nozzle size of 0.3 or 0.5mm. The assembly also has a fan and integrated duct for cooling the top of a print.

• Quick changeover print head assembly. Useful for swapping between two print head assemblies, eg. one for ABS and one for PLA. The prototypes use connection blocks, but the kit will have proper connectors. Please, note: the standard kit only contains parts for one off print head assembly.

Deltas are everywhere ... here is new one by AndyCart ...

From Thingiverse description:

This is my own variant of a variety of 3D printer designs available. I have used ideas from Kossel, Delta Pi, 3DR and, of course, Rostock. Many thanks to the designers of those machines for their brilliant ideas that I have shamelessly 'Cherry Picked' hence the name of my design!
The rods on my printer are 277mm from steel ball centre to centre. The towers are 800mm Bosch/Rexroth aluminium extrusion and the base frame extrusions are 250mm long as are, obviously, the top frame extrusions. You need nine in all.
The bearing carriers use 6 623 10mm x 4mm x 3mm bearings and slide directly on the extrusion. Nut traps for M3 nuts are included in the carrier. The rods connect to the carrier with a plate that fastens with 3 M3 bolts, again nut traps are included. The rod carriers and the effector plate hold 10mm x 5mm countersunk, cylindrical rare earth magnets and my rod end balls are 8mm diameter. My rods are 5mm carbon tube but you could use 6mm aluminium. My rod end balls have a 10mm M5 threaded rod and are the type used for the ends of gas struts, etc. the idea of the seperate rod carriers was to enable different rod attachment methods but the magnets and balls have worked out fine for me.

http://www.thingiverse.com/thing:210028

Solidus Labs Dogleg GDR Delta 3d printer is interesting variation of RepRap Simpson. Information is limited, hopefully more will be available soon.



From video description:

First movements of our dogleg grounded delta robot(GDR) 3d printer. This is the first motion test using the delta marlin firmware on a gen 6 board controlled through printrun. The GDR idea is from the Simpson 3d printer but we utilize lead screw/worm gears for motion

Source:

http://www.youtube.com/channel/UCS9dnQROWtxe3Tqcf3pWnYQ?feature=watch

Update here:

http://diy3dprinting.blogspot.com/2014/01/developments-in-reprap-simpson-family.html

From video description:

Didn't mean to be misleading - this video is time lapse. Print speed is 60mm/s - times 4.
Calibration is simple - just calibrate the bottom bed and then adjust the three intermediate platforms to the correct height and level.
The guide rods are as-supplied length of six feet, effective build height is ~150mm/platform. A single belt and NEMA17 motor drives each apex. Using T5 with printed pulleys and I'll happily compare print quality with anyone who wants to argue the merits of GT profiles:)

 The design is based on MOST Delta 3d printer which has very detailed building guide:

http://diy3dprinting.blogspot.com/2013/12/appropedia-most-delta-3d-printer.html

Brandon Heller made this Delta with very innovative and interesting design.

From project description:

SkyDelta is a new style of open-source RepRap 3D printer. Similar to deltabots like the Kossel, Rostock, Cerberus, Wolfstock, and many others, it has a triangular-prism frame. However, instead of using linear rails and rigid rods to move the print head through space, SkyDelta employs tensioned lines.

Detailed post about SkyDelta:

http://designmakeshare.wordpress.com/2013/09/16/introducing-skydelta/

SykDelta Github:

https://github.com/brandonheller/skydelta/

Nicholas Seward does it again. LISA (LInear Simpson Alternative) makes first moves in this video.




The design goals of the RepRap Lisa Simpson project are:

• Make a Rostock style bot that is capable of high speeds with a threaded rod.
• Minimize the number of components.
• Eliminate all spherical joints in favor of 608 bearing joints.
• Eliminate the smooth rods and linear bearings if possible.
• Look cool.
• Mount the steppers as low as possible.
• Eliminate all unnecessary supports.

Development forum with in-depth infromation:

http://forums.reprap.org/read.php?178,267835

Update:

Lisa is now printing good parts:

http://diy3dprinting.blogspot.com/2014/01/reprap-lisa-makes-first-good-prints.html

This could be useful for you Delta owners. MAD fellows upgraded a Deltabot into cnc mill. They are milling only foam and frozen jello for testing . They wont to use this mill to create molds for metal casting.





http://madfellowstech.com/upcycled-deltabot-project-a-success/

http://madfellowstech.com/direct-to-grilled-cheese-and-jello-cnc-delta-bot-mill/

You can now build this great looking delta yourself. Boots industries released the files since their new printer BI v2.0 is coming out.












From Thingiverse description:

Ask questions in our forums.
Learn how to strings the towers here.
Learn how to calibrate the towers here.
Learn how to properly calibrate the Ramps 1.4 pots here.
The Rostock BI V1.0 was sold at Boots Industries in fully assembled and kit form.
Our popular version of the Rostock printer by Johann features a cable drive and several other key modifications/improvements.
All parts shown were printed using our Super Premium PLA Filament.
Comes with everything you need to build your own or improve upon the design:
All Sketchup models, ready to print stl trays and additional exploded view models and pictures.
Don't hesitate to contact us if you want help with your build!

Quick specs:

• Printer Dimensions (LxWxH): 380 mm X 330 mm X 580 mm
• Build Volume (cylindrical): 170 mm Diameter X 155 mm Height
• Maximum Operating / Printing Speed: 200 mm/s
• Minimum Layer-height: 100 Microns (0.10 mm)

http://www.thingiverse.com/thing:164965

Here is detailed instruction video on how to use ceramic delta 3d printer by Jonathan Keep. It explains basic software operations with Repetier host, clay preparation, clay printing etc. Very interesting.




First post about this ceramic delta:

http://diy3dprinting.blogspot.com/2013/06/delta-ceramic-printer-by-jonathan-keep.html


http://www.keep-art.co.uk/Self_build.html

Technical Specifications:

• Printing technology: Fused Filament Fabrication (FFF / FDM)
• 18cm + diameter x 33 cm + high build volume (8000 cm3 or more)
• Precision: min 0.05mm / max 0.3mm
• Filament: Ø 1.75mm PLA
• Print speed: 100 mm / s
• Nozzle moving speed (max): 300 mm / s
• Machine Dimensions: 37 x 42 x 76 cm
• Power Supply: AC 100 - 240V, ~ 2 amps, 50-60 Hz
• Power Requirements: 12V DC @ 5 amps
• Ports: USB, SD Card
• Software: Repetier Host
• Weight: 8kg
• NEMA17 1.8° step angle 1/16 micro-stepping”

Source:

http://personalfactory.tumblr.com/post/64220942507/on-oct-4-2013-alt-design-launches-its-new-atom

http://www.youtube.com/channel/UC79uOK_dJDKLKHUyRlb8c_g?feature=watch