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{{Parts infobox
|image          = Frame-5.png
|designers      = Phil Jergenson, Ken Isaacs, Tim Schmidt
|date            = 1987
|vitamins        =
|materials      = [[Woods]], [[Aluminums]], [[Steels]], [[Plastics]], [[Fiber reinforced resins]]
|transformations = [[Milling]], [[Drilling]], [[Punching]], [[Cutting]]
|lifecycles      =
|tools          = [[Drill presses]], [[Automated drilling machines]], [[CNC routers]], [[Punch presses]], [[Sanding blocks]]
|parts          =
|techniques      = [[Bolting]], [[Tri joints]], [[Shelf joints]], [[Count by fives]], [[Divisible by two]], [[Center holes]]
|files          =
|suppliers      =
|git            =
}}


[[File:Perforatedtube.jpg|thumb]]
[[Category:Parts]]
[[File:Flat pack frame.jpg|thumb]]
[[Category:Structure parts]]
[[File:Delivery.jpg|thumb]]
[[File:Frame delivery.jpg|thumb]]


= Problem =
=Introduction=
Most projects require a physical structure.  Sizes, shapes, and configurations vary widely.   
The modular frames in this system are constructed using only one component, repeated and assembled in a variety of configurations attached using [[nuts]], [[bolts]], and [[washers]].  These frames assemble quickly, intuitively, and squarely in all dimensions and on uneven surfaces, under water, or in zero gravity.  Frame members are easily manufactured from renewable and widely available raw  materials such as trees, square steel, aluminum, and other metal tube, even bamboo and
recycled thermoplastics.  Aluminum frame members retain perfect interchangeability and reusability after years of
intense sun exposure, submersion in water, etc.  Wood frame members retain near-perfect interchangeability and reusability across lifetimes when stored in a home, or other controlled environment.
 
=Challenges=
Most projects require a physical structure.  Sizes, shapes, and configurations vary widely.  Welding requires special skills and equipment.  Aluminum extrusion, widely used, can be frustrating to insert nuts into channels in already assembled frames, and the infinite adjustability of the extruded channel requires measurement tools at assembly time and great care and attention to detail.
 
<youtube>IcVu7G71N50</youtube>
<youtube>x30Sq6aq0wY</youtube>
 
=Approaches=
Construct projects using a standardized [https://en.wikipedia.org/wiki/Space_frame space frame] kit optimized for local production.  Unlike Isaacs or Jergensen frames, Replimat uses only lengths that are multiples of 5 segments: 200 mm or approximately 7.5 inches. Frames of two, three, and four segment lengths are included to allow for the construction of additional joints and assemblies.
<gallery>
Perforatedtube.jpg|
Flat pack frame.jpg|
Delivery.jpg|
Frame delivery.jpg|
Flat pack frame2.jpg|Flat pack frame by [https://twitter.com/Ian_Willey/status/610420168783724544 Ian Willey]
</gallery>


= Approach =
<youtube>avdOxtKywbk</youtube>
Construct projects using a standardized [https://en.wikipedia.org/wiki/Space_frame space frame] kit optimized for local production.


=== Profile ===
==Profile==
Replimat frames are constructed using standard lengths of material with a square profile or cross-section. Frame sections may be solid or hollow, constructed from a single piece, laminated, or joined.  All Replimat frame sections share the same width, which is 1.5 inches (38.1 millimeters) across each side. Frames of larger or smaller widths may be produced, and work with all of the construction techniques found here.  Frames of evenly divisible widths interoperate.
Replimat frames are constructed using standard lengths of material with a square profile or cross-section. Frame sections may be solid or hollow, constructed from a single piece, laminated, or joined.  All Replimat frame sections share the same 40mm width. Frames of larger or smaller widths may be produced, and work with all of the construction techniques found here.  Frames of evenly divisible widths interoperate.


=== Widths ===
Spaceframes constructed similarly are possible using other profiles.  Hexagonal profile frame may be capable of building sections of [https://en.wikipedia.org/wiki/Weaire%E2%80%93Phelan_structure Weaire–Phelan structures].
Frames of larger cross section require fewer holes than frames of smaller cross section that are the same length.  Counterintuitively, thicker frame is sometimes faster or less expensive to produce than thinner frame.  Thicker frame also creates stronger [[tri-joints]] and requires fewer nuts and bolts to create frames of equivalent size and strangth as compared to frame of reduced width. Thinner frame can allow accurate and reproducible model building before final assembly at larger scale. Thinner frame also allows for a finer resolution in the hole pattern, easing complex mounting problems.


=== Hole Pattern ===
== Hole Pattern ==
Holes are centered on each face of the frame and spaced regularly in a repeating pattern at a distance equal to the width of the frame. This geometrical arrangement allows the frame members to reliably produce rigid joints in three dimensions.
Holes are centered on each face of the frame and spaced regularly in a repeating pattern at a distance equal to the width of the frame. This geometrical arrangement allows the frame members to reliably produce rigid joints in three dimensions.


=== Lengths ===
==Widths==
Frame lengths are intentionally limited to 2, 3, 4, 5, 10, 15, 20, 25, 30, 35, 40, 50, 60, 80, and 100 holes per side. These lengths have been chosen to allow for the creation of all necessary joint configurations (using lengths 2, 3, 4, and 5) as well as to allow for lengths with a center hole and lengths which are evenly divisible by two. The reduced set of lengths allows for improved reuse from project to project, easier identification in photographs and diagrams, and simpler production, handling, and shipping.
Frames of larger cross section require fewer holes than frames of smaller cross section that are the same length.  And fewer saw cuts when working from lumber or [[sheets]].  Counterintuitively, thicker frame is sometimes faster or less expensive to produce than thinner frame.  Thicker frame also creates stronger [[tri joints]] and requires fewer nuts and bolts to create frames of equivalent size and strength as compared to frame of reduced width.  Thinner frame can allow accurate and reproducible model building before final assembly at larger scale. Thinner frame also allows for a finer resolution in the hole pattern, easing complex mounting problems.


=== Nuts and bolts ===
==Lengths==
Frame sections are joined together using three lengths of [[bolts]], suitable for 1, 2, or 3 stacked frames and share a single size of [[washers]] and [[nuts]].
Replimat uses frame lengths of 2, 3, 4, 5, 10, 15, 20, 25, and 30 holes per side. These lengths have been chosen to allow for the creation of all necessary joint configurations as well as to allow for lengths with a center hole and lengths which are evenly divisible by two. Reducing the set of lengths allows for improved reuse from project to project, easier identification in photographs and diagrams, and simpler production, handling, and shipping.  Projects in this wiki make use of only these 9 lengths and rely on [[trusses]], [[splicing frames]], [[stacked washers]], and adapter [[plates]] to reach arbitrary positions.


=== Tools ===
{| class="wikitable"
Frame assembly requires two 13mm [[wrenches]]. A socket wrench or battery powered electric socket wrench are highly recommended for quick and easy [dis]assembly.
|+ Comparison of whole unit frame lengths - 200mm has been chosen as a base unit
|-
! 8mm width !! 20mm width !! 25.4mm width !! 38.1mm width !! 40mm width !! 50mm width !! 60mm width
|-
| 8mm ||  ||  ||  ||  ||  ||
|-
| 16mm ||  ||  ||  ||  ||  ||
|-
| 24mm ||  || 25.4mm ||  ||  ||  ||
|-
| 32mm ||  ||  ||  ||  ||  ||
|-
| 40mm || 40mm ||  ||  || 40mm ||  ||
|-
| 48mm ||  || 50.8mm ||  ||  || 50mm ||
|-
| 56mm ||  ||  ||  ||  ||  ||
|-
| 64mm ||  ||  ||  ||  ||  ||
|-
| 72mm ||  ||  ||  ||  ||  ||
|-
| 80mm || 80mm || 76.2mm || 76.2mm || 80mm || ||
|-
| 88mm ||  ||  ||  ||  ||  ||
|-
| 96mm ||  ||  ||  ||  ||  ||
|-
| 104mm ||  || 101.2mm ||  ||  || 100mm ||
|-
| 112mm ||  ||  || 114.3 ||  ||  ||
|-
| 120mm || 120mm ||  ||  || 120mm  ||  || 120mm
|-
| 128mm ||  || 126.6mm ||  ||  ||  ||
|-
| 136mm ||  ||  ||  ||  ||  ||
|-
| 144mm ||  ||  ||  ||  ||  ||
|-
| 152mm ||  || 152.4mm || 152mm ||  || 150mm ||
|-
| 160mm || 160mm ||  ||  || 160mm ||  ||
|-
| 168mm ||  ||  ||  ||  ||  ||
|-
| 176mm ||  || 177.4mm ||  ||  ||  ||
|-
| 184mm ||  ||  ||  ||  ||  || 180mm
|-
| 192mm ||  ||  || 190.5 ||  ||  ||
|-
| 200mm || 200mm || 202.8mm ||  || 200mm || 200mm ||
|-
| 208mm ||  ||  ||  ||  ||  ||
|-
| 216mm ||  ||  ||  ||  ||  ||
|-
| 224mm || 220mm || 228.6 || 228.6 ||  ||  ||
|}


=== Joints ===
Three frame sections can be joined with three nuts and bolts to form a strong three dimensional joint orienting each frame section perpendicular to the others, called a tri-lapping joint or [[tri-joint]].  Other joining techniques allow for triangular and hinged joints, which are sufficient to build several useful linkages including the Peaucellier–Lipkin linear motion linkage, Jansen’s linkage, leading link suspension, and more.
=== Off-pattern holes ===
<gallery>
<gallery>
Offset frame.jpg|Offset Frame
Frame-2.png|2 hole frame - smallest frame useful for making [[tri joints]]
Frame-3.png|3 hole frame - often useful to create spurs, mount points, and [[clevis fasteners]], smallest of the frames with [[center holes]]
Frame-4.png|4 hole frame - sometimes required for linkages and structural elements
Frame-5.png|5 hole frame - [[count by fives]] which have [[center holes]] and can accommodate two [[tri joints]] each
Frame-10.png|10 hole frame - "a ten"
Frame-15.png|15 hole frame - this size works great for larger pivoting mechanisms thanks to it's [[center holes|center hole]]
Frame-20.png|20 hole frame - desk or counter top height
Frame-25.png|25 hole frame - the largest of the frames with [[center holes]]
Frame-30.png|30 hole frame - makes great shelves
</gallery>
</gallery>


==Variations==
In the imperial version, popular hole sizes are 21/64 inch and popular bolt sizes are 5/16 inch. For the metric frames, we can use a 6 mm bolt and 7-8 mm holes for the 25 mm frame; a 12 mm bolt and holes for the 40 mm frame and 13-14 mm holes for the 50 mm frame.


=== Materials ===
==Materials==
====Steel / Aluminum====
[http://en.wikibooks.org/wiki/Robotics/Design_Basics/Building_Materials Wikibooks: robot building materials] implies that cardboard (!) is best for quick prototypes; for functional robots, "wood is probably the best material to start with."; where wood isn't quite durable enough, aluminum is the best metal -- better than steel for most robots.
=====United states=====
===Steel / Aluminum===
====United states====
*Any construction steel supplier.
*Any construction steel supplier.
* [https://8020.net/9701.html 8020 Inc Ready Tube]
* [https://8020.net/9701.html 8020 Inc Ready Tube]
Line 48: Line 143:
* [http://www.s-squaretube.com/Products/ProductDetails/tabid/85/ProductID/13/Default.aspx S-Square Square Post Perforated]
* [http://www.s-squaretube.com/Products/ProductDetails/tabid/85/ProductID/13/Default.aspx S-Square Square Post Perforated]
* Ultimate Highway Products Ulti-Mate steel highway sign posts
* Ultimate Highway Products Ulti-Mate steel highway sign posts
* [https://www.hemptraders.com/ Hemptraders]
* [https://www.markstaar.com Markstaar recycled plastic lumber]
* [https://www.tnutz.com/ TNutz]


=====Canada=====
====Canada====
*Any construction steel supplier.
* Any construction steel supplier.
*Unistrut
* Unistrut
=====UK=====
* [https://makerparts.ca/ Makerparts.ca]
* [https://spool3d.ca/parts/aluminum-extrusion/ Spool3D.ca]
* [https://us.misumi-ec.com/service/promotion/canada/ Misumi Canada]
* [https://store.cpiautomation.com/ CPI Automation]
 
====UK====
*Any construction steel supplier.  (Undrilled)
*Any construction steel supplier.  (Undrilled)
=====New Zealand=====
====New Zealand====
<sbailard_> VikOlliver, steel and aluminum box section down in NZ, is it metric, or '25.4 mm'?
<sbailard_> VikOlliver, steel and aluminum box section down in NZ, is it metric, or '25.4 mm'?
<VikOlliver> Strangley it's in approx 25mm increments...
<VikOlliver> Strangley it's in approx 25mm increments...
* sbailard_ is beside himself in surprise.
* sbailard_ is beside himself in surprise.
<VikOlliver> It's sold as 25x50mm box section but you know what they mean...
<VikOlliver> It's sold as 25x50mm box section but you know what they mean...
 
* https://www.ullrich-aluminium.co.nz/extrusions/square-tube
* https://www.easysteel.co.nz/products/hollow-sections
 
====China====
* [https://www.aliexpress.com/store/1752067?spm=2114.12010612.pcShopHead_12407346.0 Bulkman 3D]


====Wood====
===Wood===
=====Warning=====
====Michigan====
In North America, {{tag|wood}} which is called '1x1' or '2x2' is actually smaller than 1 inch or 2 inches in cross section.  This is unfortunate but legal.  Speak to a lumber yard or other supplier about getting 'wood which is actually sized 1 inch by 1 inch or 2 inches by 2 inches'.  They will be able to help you, possibly by setting up a small order correctly sized material with a local mill, which may be a quick job.  (If you are a woodworker, this paragraph is obvious, and we apologize.  And you have a table saw.)
* [https://www.michigan.gov/documents/dnr/industry_directory_535236_7.pdf WOOD PRODUCTS IN MICHIGAN PART I - A Directory of Primary Mills and Manufacturers]
 
====Warning====
In North America, wood which is called '1x1' or '2x2' is actually smaller than 1 inch or 2 inches in cross section.  This is unfortunate but legal.  Speak to a lumber yard or other supplier about getting 'wood which is actually sized 1 inch by 1 inch or 2 inches by 2 inches'.  They will be able to help you, possibly by setting up a small order correctly sized material with a local mill, which may be a quick job.  (If you are a woodworker, this paragraph is obvious, and we apologize.  And you have a table saw.)


A common so-called "two-by-four" (38 mm x 89 mm, 1.5 inch x 3.5 inch)
A common so-called "two-by-four" (38 mm x 89 mm, 1.5 inch x 3.5 inch)
can be ripped and planed into two separate grid beams (each 38 mm square).
can be ripped and planed into two separate grid beams (each 38 mm square).
Does it make any sense to do slightly less work, converting that so-called "2x4 board" into one beam that acts like those 2 grid beams permanently attached to each other, 38 mm x 76 (1.5" x 3.0") with a double row of holes on the 3.0" wide side?  
Does it make any sense to do slightly less work, converting that so-called "2x4 board" into one beam that acts like those 2 grid beams permanently attached to each other, 38 mm x 76 (1.5" x 3.0") with a double row of holes on the 3.0" wide side?


====Notes====
*Nails - After checking carefully with a nail finder.
*Nails - After checking carefully with a nail finder.
*Grit - Use a stiff plastic brush to clean off your wood.  Stone pebbles will chip your saw blade.
*Grit - Use a stiff plastic brush to clean off your wood.  Stone pebbles will chip your saw blade.


==Similar Construction Systems==
===Plastics===
* [http://www.contraptor.org/forum/t-273404/contraptor-openstructures Metric Contraptor adapted to the OpenStructures OSGrid]
<youtube>zNGuuSKE1pY</youtube>
* [http://microrax.com/ MicroRax]
* [http://www.lynxmotion.com/ Lynxmotion]
* [https://www.vexrobotics.com/ Vex Robotics]
* [https://www.pitsco.com/Shop/TETRIX-Robotics/ TETRIX Robotics]
* [https://www.dexionstore.co.uk/dexion-speedframe-c-3234_3219_564.html Dexion Speedframe]
* VSlot,
* fischertechnik aluminum beams,
* 80/20 beams,
* MakerBeam,
* OpenBeam,
* [https://www.boschrexroth.com/en/xc/products/product-groups/assembly-technology/topics/aluminum-profiles-solutions-components/index Bosch Rexroth Profiles]
* [https://www.item24.de/en/home.html item Aluminum Profiles (the original)]
* [https://www.mk-group.com/en/products/profile-technology/profile-system.html MK Aluminum Profile System]
* pegboard: wood sheets with a regular grid drilled into them
* slatwall (Is this the same as T-slots routed into MDF ?) [http://kregjig.ning.com/forum/topics/i-need-t-track]
* fischertechnik parts -- [[FTIStrap]] is the first RepStrap to succeed in printing 3D objects
* the [http://www.lynxmotion.com/Category.aspx?CategoryID=73 "Servo Erector Set"] looks like a quick way to assemble things like a [http://www.youtube.com/watch?v=7hEXwyJ2B78 Hexapod Robot CNC Router].
* LEGO -- [[:Category:Lego]]
* [http://www.erector-sets.net/ Erector] and Meccano -- ?
* Merkur -- ?
* [http://parts.ftcrobots.com/store/Default.aspx?bhcp=1 Pitsco TETRIX Parts] -- ?
* [http://www.vexrobotics.com/products/accessories/structure VEX Robotics Design] -- ?
* The Phenostream Robotics [http://www.phenostream.com/gallery.aspx BuildPlate construction system] looks like a quick way to assemble hand-sized robots -- ?
* The [http://mrkimrobotics.com/?page_id=2209 "The 1X2 connector system"] -- [[1X2]], [[1X2 Shortcat]], and [[1X2 Tallcat]]
* [[Plastic T-slot]]
* The [http://fffff.at/free-universal-construction-kit/ Free Universal Construction Kit] is a set of adapters for interoperability between several of the above construction "toys").
* 8 mm threaded steel rod (aka "[[threaded rod]]" or "allthread" or "M8 studding"): Many RepRaps and RepStraps use all-thread as a easily-adjustable frame material. Many also have at least one axis driven by a "lead screw" of 8 mm threaded road or nearly equivalent 5/16" threaded rod that acts as a worm gear, turned by a [[stepper motor]], that pushes parts back and forth. A few use bigger sizes such as M12 and M10 threated rods in the [[BiBONE]][http://forums.reprap.org/read.php?152,128970] or smaller sizes such as the 1/4 inch threaded rod used in smaller [[SAE Mendel]] machines.
* 8 mm smooth steel rods (aka [[smooth rod]], aka "drill rod"): Most RepRaps and RepStraps have parts that slide back and forth on 8 mm or nearly equivalent 5/16" smooth rod. A few RepStraps ({{tag|DriveTrains#rotary to linear motion conversion}}) spin a smooth rod with their motor rather than a threaded rod. A few use other sizes such as the 12 mm smooth rod used by [[HaMendel]][http://forums.reprap.org/read.php?152,169733] and BiBone. "O1 drill rod" ? "A2 drill rod" ?
* [http://www.inventables.com/technologies/makerslide Makerslide]
* [http://openbuildspartstore.com/ OpenBuilds]
* [http://www.robotdigg.com/product/225/2020-Aluminum-Extrusion-in-Lengths Robot Digg]
* [https://eztube.com EZ Tube]
* [https://alcobrametals.com/products/telescoping-tube/telescoping-aluminum-square-tube/6005a-t6-telescoping-square-tube Telescoping square tube]
* [http://makeblock.cc/ Makeblock]
* The square metal tubes with round holes in the side pictured in [http://blog.reprap.org/2009/02/pull-yourself-together-bot.html "Pull Yourself Together, Bot!"] look a *lot* like grid beam -- would "real" grid beam work just as well?
* http://www.gridbeamers.com/
* http://gridbeam.biz/
* http://www.alliedtube.com/sign-support/traffic-sign-posts/telespar-square.asp
* http://www.mcmaster.com/#steel-structural-tubing/=49tu63
* [https://www.makeralot.com/2020-aluminium-extrusion-1-meter-p210/ 2020 T Slotted Aluminium Extrusion]
* [https://www.makeralot.com/2020-v-slot-aluminium-extrusion-1-meter-p211/ 2020 V Slotted Aluminium Extrusion]
* [https://www.makeralot.com/2040-v-slot-extruded-aluminum-1-meter-20mm-x-40mm-p212/ 2040 V Slotted Aluminium Extrusion]
* [https://www.makeralot.com/2060-v-slot-extruded-aluminum-profiles-1-meter-20-x-60-p213/ 2060 V Slotted Aluminium Extrusion]
* [https://www.makeralot.com/2080-v-slotted-aluminum-1-meter-vslot-20-x-80mm-aluminum-extrusion-p214/ 2080 V Slotted Aluminium Extrusion]
* [http://web.mit.edu/imoyer/www/portfolio/parametric/ "Parametrically Designed XY Motion Stage"], apparently part of the thesis "Rapid Prototyping of Rapid Prototyping Machines" by Ilan Ellison Moyer.
* [http://builders.reprap.org/2009/08/wrench-built-machine-update.html Wrench-built machine] appears to be built out of grid beam. A RepStrap built mostly out of 1" square perforated tube. ''(Is this a [[Eiffel]] or something else?)''
* [http://opensourceecology.org/wiki/LifeTrac_Questions#square_tube_construction_techniques square tube construction techniques]; [http://opensourceecology.org/wiki/gridbeam Grid Beam]
* http://www.gridbeam.com/
* http://www.gridbeamers.com/
* http://gridbeam.biz/
* http://www.alliedtube.com/sign-support/traffic-sign-posts/telespar-square.asp
* http://www.mcmaster.com/#steel-structural-tubing/=49tu63
* [http://bitbeam.org/ Bitbeam]
* MakerBeam; 80/20 T-slot extrusion; etc. -- [[T-Rep]], [[SamBot]], etc.
* [http://www.openstructures.net/ OpenStructures]
 
=== water pipe ===
 
* electrical conduit (~20 mm OD steel tube) -- [[Uconduit]]
* Steel water pipe and fittings -- [[Builders/Frank]]; [[McWire Cartesian Bot 1 2]]; [[Builders/PipeStrap]]; [[Development:McWire]]
* [[PVC]] water pipe and fittings -- much lighter weight and lower cost and easier to drill than metal; but is it rigid enough? [[XtruBot]], [[RepRap Morgan]], [[LISA Simpson]], [[Easy build delta printer]], etc.
** possibly using the [http://www.thingiverse.com/thing:932732 "PVC pipe construction set"] as described at [http://3dprint.com/84284/pvc-pipe-construction-kit/ "PVC Pipe Construction Gets Boost with 3D Printed Corner Connectors"]
* Large-diameter [[PVC]] sewer pipe -- using 6" (or larger) nominal I.D. pipe as a tower/gantry to mount the other parts of the printer. [[PipeDream]]
 
=== other cut-to-length construction materials ===
 
* low-cost softwood dimensional lumber, roughly 18x45mm and 18x70mm (close enough to "1x2" and "1x4"), bolted together -- [[1X2]] and [[WolfStrap]]
* poplar planks -- [http://3dreplicators.com/New%20Front%20Page/Gallery/Gallery.htm Tommelise]
* extruded aluminum L rails -- [[Doboz]]
* [[#extruded aluminum]] in other shapes
 
== cut-to-shape construction materials ==
 
''Should we distinguish between cutting flat materials into a (2D) shape (perhaps with a [[CNC Router]]) and perhaps drilling a few holes into the face and edges, vs. cutting large blocks of material into arbitrary 3D shapes?''
 
* cut sheets without any plastic printed parts (RepStrap):
** sheet metal cut, drilled, and folded to approximate the plastic parts of a Mendel -- [[My Development Page Sheet Metal Mendel]]
** sheet metal cut, drilled, and folded in other ways -- [http://www.youtube.com/watch?feature=player_embedded&v=rU9ef3tBvk4 Tony's sheet metal RepStrap]
** "MDF or Ply or Perspex/Acrlic or HDPE or Aluminum" sheets -- [[Huxley Seedling]]
** laser-cut plastic (typically clear acrylic) -- [[Builders/LaserCut RepStraps]]; [[PonokoRepRap]]
** sheet plywood -- [[PlywoodRepRaps]] such as [[LaserCut Mendel]]; [[CupCakeStrap]]; [[CupCake]] ??? ; [[Gunstrap]]; [[DeltaTrix]] ([http://www.deltatrix.co.uk/]; [http://www.instructables.com/id/DeltaTrix-3D-Printer]); etc.
 
** foamcore -- see imoyer's Foamcore CNC Machine [http://web.mit.edu/imoyer/www/portfolio/foamcore/] [http://reprap.development-tracker.info/development/143002] [http://www.instructables.com/id/Build-a-Foamcore-CNC/]. Can this be laser-cut?
** "flat sheets of wood or plastic (currently HDPE) ... Cut ... on some 2.5D CNC router" -- [[Isaac]], [[LaserCut Mendel]], etc.
* hardwood cut in more or less the exact same shapes as the plastic parts of a Mendel -- [[Development:Wooden Mendel]]
* metal cut in more or less the exact same shapes as the plastic parts of a Mendel -- [[Development:Metal Mendel]]
* ??? -- [[Development:McWire Successor]] ???
* adapting an off-the-shelf milling machine -- [[:Category:MillStrap]]
* whatever random stuff I had laying around -- [[Builders/JunkStrap]]
* Hybrid: cut sheets and plastic printed parts complementing each other:
** Hybrid: Medium Density Fiberboard (MDF) or Acrylic sheet with printed brackets -- [[Mendel90]]; [[Prusa i3#Wood Sheet frame]]; [[Prusa i3#Box Style Frame]];
** 4 mm aluminum sheet metal and printed brackets -- [[Orca]]
** 6 mm aluminum sheet metal and printed brackets -- [[Prusa i3#Single Sheet Frame]]
** Dibond: [[Idea lab one]], [[Mendel90]], etc.
 
To make future generations of self-replicating machines out of such materials seems to require a [[CNC Router]] or a [[Laser Cutter]].
 
== other discussions of building material ==
 
* [http://en.wikibooks.org/wiki/Robotics/Design_Basics/Building_Materials Wikibooks: robot building materials] implies that cardboard (!) is best for quick prototypes; for functional robots, "wood is probably the best material to start with."; where wood isn't quite durable enough, aluminum is the best metal -- better than steel for most robots.
** ''Is "edgeboard"[https://web.archive.org/web/20100804002012/http://www.arcspace.com/gehry_new/index.html?main=/gehry_new/cardb/cardb.html] the same as corrugated cardboard? It's apparently strong enough to hold up full-sized humans; is it strong enough to hold up an extruder nozzle?''
** ''Is it possible to build a [[FlatPack]] RepStrap mostly out of "Laminated Laser-cut Cardboard"[http://forums.reprap.org/read.php?178,64851]?''
*** [http://www.erb.co.il/en/cooperations.asp Izhar Gafni] has made a type of bicycle with a composite frame (''cardboard & epoxy?/some polyester?'') ("[http://www.dezeen.com/2012/11/12/cardboard-bicycle-by-izhar-gafni/ Cardboard Bicycle]"). It is apparently waterproof and strong enough to hold up full-sized humans. It is definitely worth an investigation, if nothing else for the other end of the M8 threaded rod there.. are on several levels; [[Epoxy_granite|Epoxy Granite]].
 
<videoflash type="vimeo">37584656</videoflash>
 
* [[User:Mrkim]] mentions various "Classes of machines",[http://mrkimrobotics.com/?page_id=2209][http://www.thingiverse.com/thing:5773] including entire classes of machines that the above seems to neglect.
 
* [https://carnesmechanical.com Carnesmechanical] strive to create a collaborative environment to make the purchase of automotive products enjoyable for you. Carnesmechanical is a small blog, is dedicated to bringing unbiased automotive product reviews, car Electronics, auto tool, oil, electrical, welding, accessories.
 
{{OpenJSCAD|title=CAD|code=
// Here we define the user editable parameters:
function getParameterDefinitions() {
  return [
    { type: 'float', name: 'beam_width', caption: 'Beam width', default: 38.1 },
    { type: 'float', name: 'hole_radius', caption: 'Radius of holes', default: 8 },
    { type: 'choice', name: 'length', caption: 'Frame length (holes)', values: [2,3,4,5,10,15,20,25,30,35,40,45,50,55,60,70,80,90,100], captions: ["2","3","4","5","10","15","20","25","30","35","40","45","50","55","60","70","80","90","100"], default: 10 }
  ];
}
 
// zBeam(length) - create a vertical bitbeam strut 'length' long
// xBeam(length) - create a horizontal bitbeam strug along the X axis
// yBeam(length) - create a horizontal bitbeam strut along the Y axis
// translateBeam(beam, [x, y, z]) - translate bitbeam struts in X, Y, or Z axes in units 'beam_width'
 
var cylresolution=16;
var beam_width=38;
var hole_radius=8;
 
function main(params) {
 
    cylresolution=(params.quality == "1")? 64:16;
    beam_width=params.beam_width;
    hole_radius=params.hole_radius;
    return xBeam(params.length);
}
 
function xHole(i) {
    return CSG.cylinder( {
        start: [-1, beam_width/2, i*beam_width + beam_width/2],
        end: [beam_width+1, beam_width/2, i*beam_width + beam_width/2],
        radius: hole_radius,
        resolution: cylresolution
    } );
}
 
function yHole(i) {
    return CSG.cylinder( {
        start: [beam_width/2, -1, i*beam_width + beam_width/2],
        end: [beam_width/2, beam_width+1, i*beam_width + beam_width/2],
        radius: hole_radius,
        resolution: cylresolution
    } );
}
 
function zBeam(length) {
    var cube = CSG.cube({
        center: [beam_width/2, beam_width/2, (length*beam_width)/2],
        radius: [beam_width/2, beam_width/2, (length*beam_width)/2]
        });
    var holes = [];
    for (var i = 0; i < length; i++)
    {
        holes.push(xHole(i));
        holes.push(yHole(i));
    }
    var beam = cube.subtract(holes);
    beam.properties.myConnector = new CSG.Connector([10, 0, 0], [1, 0, 0], [0, 0, 1]);
    return beam;
}
 
function yBeam(length) {
    return translateBeam(zBeam(length).rotateX(-90), [0,0,1]);
}
 
function xBeam(length) {
    return translateBeam(zBeam(length).rotateY(90), [0,0,1]);
}
 
function translateBeam(beam, t_vector) {
    return beam.translate(t_vector.map(function(n) { return beam_width*n; }));
}
 
}}


[[Category: Parts]]
=References=
* [https://hackaday.com/2021/05/25/getting-started-with-aluminum-extrusions/ Getting started with aluminum extrusions]
* https://www.amazon.com/dp/B07P7BKXY7/ref=cm_sw_r_cp_apa_i_w83gFbG078T8M?tag=replimat-20
* [https://hackaday.com/2016/12/14/a-how-to-in-homebrew-design-fab-and-assembly-with-extruded-profiles/#more-232250 A How-To in Homebrew Design, Fab, and Assembly With Extruded Profiles]
* [https://ssb.muchmuch.coffee/%25bUttGn66HTaK16QNp7XBB%2B4fWlNnTPpOfpIUfRxHX3s%3D.sha256 discussion of frame production techniques]
* [https://www.atthatmatt.com/research/grand-unification-theory-of-modular-units/ Grand unification theory of modular units]
* [https://tojagrid.com Toja grid pergola system] - 4x4 brackets are 14-gauge and 6x6 brackets are 12-gauge steel, 10 year powder coating, 5 year warranty.
* [https://github.com/marialarsson/tsugite Interactive Design and Fabrication of Wood Joints]
* [https://www.bullmoosetube.com/wp-content/uploads/2020/06/HSS_Beam_Load_Tables.pdf HOLLOW  STRUCTURAL SECTIONS Beam Load Tables]
* [https://sacr3detching.com/ Sacr3D Etching]
<youtube>ozSE7Wrdb1o</youtube>

Latest revision as of 06:49, 4 March 2023

Part: Frames
Designers: Phil Jergenson, Ken Isaacs, Tim Schmidt
Materials: Woods, Aluminums, Steels, Plastics, Fiber reinforced resins
Transformations: Milling, Drilling, Punching, Cutting
Tools: Drill presses, Automated drilling machines, CNC routers, Punch presses, Sanding blocks
Techniques: Bolting, Tri joints, Shelf joints, Count by fives, Divisible by two, Center holes

Introduction

The modular frames in this system are constructed using only one component, repeated and assembled in a variety of configurations attached using nuts, bolts, and washers. These frames assemble quickly, intuitively, and squarely in all dimensions and on uneven surfaces, under water, or in zero gravity. Frame members are easily manufactured from renewable and widely available raw materials such as trees, square steel, aluminum, and other metal tube, even bamboo and recycled thermoplastics. Aluminum frame members retain perfect interchangeability and reusability after years of intense sun exposure, submersion in water, etc. Wood frame members retain near-perfect interchangeability and reusability across lifetimes when stored in a home, or other controlled environment.

Challenges

Most projects require a physical structure. Sizes, shapes, and configurations vary widely. Welding requires special skills and equipment. Aluminum extrusion, widely used, can be frustrating to insert nuts into channels in already assembled frames, and the infinite adjustability of the extruded channel requires measurement tools at assembly time and great care and attention to detail.

Approaches

Construct projects using a standardized space frame kit optimized for local production. Unlike Isaacs or Jergensen frames, Replimat uses only lengths that are multiples of 5 segments: 200 mm or approximately 7.5 inches. Frames of two, three, and four segment lengths are included to allow for the construction of additional joints and assemblies.

Profile

Replimat frames are constructed using standard lengths of material with a square profile or cross-section. Frame sections may be solid or hollow, constructed from a single piece, laminated, or joined. All Replimat frame sections share the same 40mm width. Frames of larger or smaller widths may be produced, and work with all of the construction techniques found here. Frames of evenly divisible widths interoperate.

Spaceframes constructed similarly are possible using other profiles. Hexagonal profile frame may be capable of building sections of Weaire–Phelan structures.

Hole Pattern

Holes are centered on each face of the frame and spaced regularly in a repeating pattern at a distance equal to the width of the frame. This geometrical arrangement allows the frame members to reliably produce rigid joints in three dimensions.

Widths

Frames of larger cross section require fewer holes than frames of smaller cross section that are the same length. And fewer saw cuts when working from lumber or sheets. Counterintuitively, thicker frame is sometimes faster or less expensive to produce than thinner frame. Thicker frame also creates stronger tri joints and requires fewer nuts and bolts to create frames of equivalent size and strength as compared to frame of reduced width. Thinner frame can allow accurate and reproducible model building before final assembly at larger scale. Thinner frame also allows for a finer resolution in the hole pattern, easing complex mounting problems.

Lengths

Replimat uses frame lengths of 2, 3, 4, 5, 10, 15, 20, 25, and 30 holes per side. These lengths have been chosen to allow for the creation of all necessary joint configurations as well as to allow for lengths with a center hole and lengths which are evenly divisible by two. Reducing the set of lengths allows for improved reuse from project to project, easier identification in photographs and diagrams, and simpler production, handling, and shipping. Projects in this wiki make use of only these 9 lengths and rely on trusses, splicing frames, stacked washers, and adapter plates to reach arbitrary positions.

Comparison of whole unit frame lengths - 200mm has been chosen as a base unit
8mm width 20mm width 25.4mm width 38.1mm width 40mm width 50mm width 60mm width
8mm
16mm
24mm 25.4mm
32mm
40mm 40mm 40mm
48mm 50.8mm 50mm
56mm
64mm
72mm
80mm 80mm 76.2mm 76.2mm 80mm
88mm
96mm
104mm 101.2mm 100mm
112mm 114.3
120mm 120mm 120mm 120mm
128mm 126.6mm
136mm
144mm
152mm 152.4mm 152mm 150mm
160mm 160mm 160mm
168mm
176mm 177.4mm
184mm 180mm
192mm 190.5
200mm 200mm 202.8mm 200mm 200mm
208mm
216mm
224mm 220mm 228.6 228.6
  • 2 hole frame - smallest frame useful for making tri joints

    2 hole frame - smallest frame useful for making tri joints

  • 3 hole frame - often useful to create spurs, mount points, and clevis fasteners, smallest of the frames with center holes

    3 hole frame - often useful to create spurs, mount points, and clevis fasteners, smallest of the frames with center holes

  • 4 hole frame - sometimes required for linkages and structural elements

    4 hole frame - sometimes required for linkages and structural elements

  • 5 hole frame - count by fives which have center holes and can accommodate two tri joints each

    5 hole frame - count by fives which have center holes and can accommodate two tri joints each

  • 10 hole frame - "a ten"

    10 hole frame - "a ten"

  • 15 hole frame - this size works great for larger pivoting mechanisms thanks to it's center hole

    15 hole frame - this size works great for larger pivoting mechanisms thanks to it's center hole

  • 20 hole frame - desk or counter top height

    20 hole frame - desk or counter top height

  • 25 hole frame - the largest of the frames with center holes

    25 hole frame - the largest of the frames with center holes

  • 30 hole frame - makes great shelves

    30 hole frame - makes great shelves

Variations

In the imperial version, popular hole sizes are 21/64 inch and popular bolt sizes are 5/16 inch. For the metric frames, we can use a 6 mm bolt and 7-8 mm holes for the 25 mm frame; a 12 mm bolt and holes for the 40 mm frame and 13-14 mm holes for the 50 mm frame.

Materials

Wikibooks: robot building materials implies that cardboard (!) is best for quick prototypes; for functional robots, "wood is probably the best material to start with."; where wood isn't quite durable enough, aluminum is the best metal -- better than steel for most robots.

Steel / Aluminum

United states

Canada

UK

  • Any construction steel supplier. (Undrilled)

New Zealand

<sbailard_> VikOlliver, steel and aluminum box section down in NZ, is it metric, or '25.4 mm'?
<VikOlliver> Strangley it's in approx 25mm increments...
* sbailard_ is beside himself in surprise.
<VikOlliver> It's sold as 25x50mm box section but you know what they mean...

China

Wood

Michigan

Warning

In North America, wood which is called '1x1' or '2x2' is actually smaller than 1 inch or 2 inches in cross section. This is unfortunate but legal. Speak to a lumber yard or other supplier about getting 'wood which is actually sized 1 inch by 1 inch or 2 inches by 2 inches'. They will be able to help you, possibly by setting up a small order correctly sized material with a local mill, which may be a quick job. (If you are a woodworker, this paragraph is obvious, and we apologize. And you have a table saw.)

A common so-called "two-by-four" (38 mm x 89 mm, 1.5 inch x 3.5 inch) can be ripped and planed into two separate grid beams (each 38 mm square). Does it make any sense to do slightly less work, converting that so-called "2x4 board" into one beam that acts like those 2 grid beams permanently attached to each other, 38 mm x 76 (1.5" x 3.0") with a double row of holes on the 3.0" wide side?

  • Nails - After checking carefully with a nail finder.
  • Grit - Use a stiff plastic brush to clean off your wood. Stone pebbles will chip your saw blade.

Plastics

References

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