3X Speed and reliability with custom rack and pinion linear actuators for my large format 3D printer.

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Having printed with hundreds of kilograms of pellets, I've experienced both the incredible potential and the limitations of my DIY Large Format 3D Printer. Further, the acquisition of a new pellet extruder, with a volumetric flow rate five times greater than its predecessor, necessitated immediate upgrades to essential parts of my printing process, including the actuators for improved speed and reliability.

In this video, I detail the process of designing and machining custom carriages to integrate rack and pinion linear motion systems for the X and Y axes (speed!) and ball screw actuators for the Z axis (reliable). I also discuss the workings of the rack and pinion system, its components, and share insights on optimizing this type of linear motion setup for peak performance


Table of Contents:
00:00​ Introduction
00:56​ Relocating Printer
02:00​ Print Speed
06:56 ZAxis Ball Screws
13:49 Ball Screw Actuator Assembly
15:08 Upgrading the Gantry
16:32 Rack and Pinion (R&P)
17:09 R&P Components
21:14 R&P Tensioning
23:48 Mounting Gear Racks
24:50 R&P Testing
28:54 R&P Actuators Assembly
37:46 Floating Printhead
40:53 Machining Carriage Plate






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