REMORPH DESIGN

Constraints defined the build size. Had to fit on most workbenches and desks, the extrusions to be cuts of 50mm increments, electronics and XY motors isolated… Those types of decisions along with the toolhead design, electronics layout, nozzle wiper and such, defined the max XY motion, which made the printable area 307×307mm. The slightly larger build plate is due to some niche reasons, mainly, not printing on the very edges, heat around when the entire area is utilized and embedded sections to grab the flexible sheet.

This isn’t just 3-point leveling. Maxwell kinematic couplers ensure even expansion and positioning. Each joint uses 12mm steel balls on two 5mm shafts, held by a 10×15×25mm magnet.

All idlers and gears use 5mm shafts with 13mm bearings.

To avoid constraining the size and weight of the toolhead components and to maintain comfortable chamber access, bigger ones made more sense than multiple small motors. But N23 steppers cap out around 1000 RPM, so for the XY, two N23 servos. The Z axis uses three N17 steppers.

The toolhead has a slide-up guard. The PCB is mounted at the front, keeping the cable close to the filament tube and providing easy access to the connectors. Components are rapidly accessible, with very few steps to reach one.

At the top of the chamber, a slide-out filter box contains three 15×40×80mm HEPA filters and 0.69L of activated carbon pellets. Both, chamber fan and part cooling fan draw air through it. The chamber fan’s exhaust is split into two outlets at the bottom of the chamber for top-down convection.

The chamber has a sealed filament storage with desiccant compartments. Spool holder sits on bearings to minimize resistance for the extruder.

Filament Y-Splitter to ease external feed.

Nozzle wiper with a slide-out bucket.