Marblevator, My Fastest Yet.

A follower challenged me to make the fastest Marblevator I could, and here's my first attempt, "Marblevator, My Fastest Yet".

As usual I probably forgot a file or two or who knows what else, so if you have any questions, please do not hesitate to ask as I do make plenty of mistakes.

Designed using Autodesk Fusion 360, sliced using Ultimaker Cura 14.12.1, and 3D printed in PLA on Ultimaker S5s.

Soldering Iron and Solder.

AWG22 stranded black and red wire.

I acquired the following parts:

1. One Micro 130 DC Motor.
2. One twin AA battery holder with wires and switch.
3. Two AA batteries.
4. Two R20 O-Rings (25mm ID, 3.5mm section).
5. One 11mm nylon sphere.
6. Twelve 6mm diameter by 2mm thick neodymium magnets.

I 3D printed the following parts at .15mm layer height, 20% infill, and no supports:

1. One "Base Base.stl".
2. One "Base Lid.stl".
3. One "Base Tower.stl".
4. Four "Bolt (M8 by 8mm).stl".
5. Four "Bolt (M8 by 17mm).stl".
6. One "Bolt (M8 by16mm).stl".
7. One "Bottom Cover.stl".
8. One "Bracket.stl".
9. One "Motor Mount.stl".
10. One "Motor Wheel.stl".
11. One "Top Cover.stl".
12. One "Track.stl".

This mechanism is a high precision print and assembly using at times very small precision 3D printed parts in confined spaces with highly precise alignment. Prior to assembly, I test fitted and trimmed, filed, drilled, sanded, etc. all parts as necessary for smooth movement of moving surfaces, and tight fit for non moving surfaces. Depending on your slicer, printer, printer settings and the colors you chose, more or less trimming, filing, drilling and/or sanding may be required to successfully recreate this model. I carefully filed all edges that contacted the build plate to make absolutely certain that all build plate "ooze" is removed and that all edges are smooth using small jewelers files and plenty of patience.

This mechanism also uses threaded assembly, so I used a tap and die set (M8 by 1.25) as required for thread cleaning.

To assemble the track, I performed the following steps:

1. Pressed two magnets into "Track.stl" matching polarities.
2. Pressed two magnets into "Top Cover.stl" matching the polarities of the track magnets.
3. Snapped the 11mm nylon sphere into the track assembly.

To assemble the base, I performed the following steps.

1. Pressed four magnets into "Base Base.stl" and four magnets into "Base Lid.stl" with matching polarities.
2. Carefully removed the battery box cover then the battery switch cover from the battery box.
3. Desoldered the existing red and black wires from the battery box switch and negative spring.
4. Soldered a 200mm length of red wire to the battery box switch.
5. Soldered a 200mm length of black wire to the battery box negative spring.
6. Carefully replaced the battery switch cover.
7. Installed two AA batteries in the battery box.
8. Replaced the battery box cover.
9. Pressed "Base Tower.stl" into the base assembly.
10. Slid the base lid assembly onto the base tower.
11. Attached "Bracket.stl" to the tower, hole side down, using one "Bolt (M8 by 16mm).stl".
12. With the lid assembly positioned half way onto the base tower, slid the free ends of the battery wires up through the base and tower, then through the hole in the bracket.
13. Positioned the battery box in the base assembly, aligned the rectangle hole in the lid with the battery box switch, then snapped the lid into position.
14. Slid the wires through the hole in "Bottom Cover.stl", then attached the bottom cover to the bracket using four "Bolt (M8 by 8mm).stl".
15. Soldered the free ends of the battery box wires to the motor such that the motor rotated clockwise as viewed from the motor shaft in of the motor when power is applied.
16. Pressed the motor into "Motor Mount,stl".
17. Slid two O-rings onto "Motor Wheel.stl".
18. Pressed the motor wheel onto the motor shaft.
19. Positioned the motor and mount into the bottom cover.

For final assembly, I performed the following steps:

1. Aligned the four bolt holes in the track assembly with the four bolt holes in the motor mount assembly and the four threaded holes in the lower cover assembly, then secured the track and motor to the lower cover using four "Bolt (M8 by 16mm).stl".
2. With power applied, carefully adjusted the motor position in the motor mount until the motor wheel assembly rotated with ease.

And that is how I 3D printed and assembled "Marblevator, My Fastest Yet".

I hope you enjoyed it!