BOM

Thunderhead Filament Extruder

Materials NOT included in Kit

Image	Name	Description	Source	Files	Qty
	Water Bath Frame				1
	Tank Sides and Bottom				1
	Tank End				2
	Foot Attachment Plate				4
	Paint^Water Bath	To keep water bath from rusting.			1
	Threaded Rod M8 by 120 mm long		Made	step, drawing	1
	Threaded Rod M8 by 70 mm long		Made	step, drawing	1
	For the following 1 parts purchase -->	Aluminum, Square Tube, 3/4 in x 3/4 in x 1/16 in			550 mm
	Vertical Bar - Guide Roller		Made	step, drawing	1
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	For the following 1 parts purchase -->	Aluminum, Tube, 1 in OD x 1/16 in Thick			695 mm
	Lower air delivery tube		Made		1
-------	---------------------	---------------------	----------	---------	---------
	For the following 1 parts purchase -->	Metal Angle, 3/4 in x 3/4 in x 1/8 in			995 mm
	Hopper - Support Angle		Made		2
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	For the following 5 parts purchase -->	Steel, Flat Bar, 1 in x 1/4 in			1883 mm
	Drive Wheel Support		Made	step, drawing	1
	Idler Bar		Made	step, drawing	1
	Outfeed Bar		Made	step, drawing	1
	Outfeed Mount Coupling		Made	step, drawing	1
	PivotBarEnds		Made	step, drawing	2
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	For the following 5 parts purchase -->	Steel, Square Tube, 1 in x 1 in x 1/16 in			12300 mm
	Hopper - Support Arm		Made		2
	Horizontal Bar - Guide Roller		Made	step, drawing	1
	Outfeed Mounting Bar 1		Made	step, drawing	1
	Stand Weldment		Made	step, drawing	1
	Support - Sensor and Outfeed		Made	step, drawing	1
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	For the following 1 parts purchase -->	Steel, Square Tube, 1 in x 1 in x 1/8 in			12491 mm
	Extruder Mounting Spacer		Made	step, drawing	1
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	Hopper - Heater Coupler Insulative Backing		Made		1
	Vinyl Tubing 3-16 in ID		Made	step, drawing	1
	For the following 4 parts purchase -->	Sheet Metal, 0.75 mm Thick			608000 mm^2
	Face Plate - Low V Electronics		Made		1
	Gear Box Cover	Make from sheet metal 22 guage or similar	Made	step, drawing	1
	High V Electronics Enclosure Base		Made		1
	High V Electronics Enclosure Top		Made		1
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	For the following 2 parts purchase -->	Sheet Metal, 1.5 mm Thick			676600 mm^2
	Auger Gear Support Disk		Made	step, drawing	2
	Base Plate - Low V Electronics		Made		1
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	For the following 19 parts purchase -->	Stainless Steel, Sheet, 0.454 mm Thick			1586600 mm^2
	Hopper - Air Inlet Bell		Made		1
	Hopper - Air Inlet Collar		Made		1
	Hopper - Electronics Back Cover		Made		1
	Hopper - Electronics Front Cover		Made		1
	Hopper - Heater Cover End		Made		1
	Hopper - Hinge		Made		4
	Hopper - Hinge		Made		4
	Hopper - Inner Solid Square Section		Made		1
	Hopper - Inner Square Funnel		Made		1
	Hopper - Lid Body		Made		1
	Hopper - Lid Handle		Made		2
	Hopper - Lower Angle		Made		2
	Hopper - Outer Solid Square		Made		1
	Hopper - Outer Square Funnel		Made		1
	Hopper - Power Supply Mount		Made		1
	Hopper - Top Ring		Made		1
	Hopper - Vent Tube Coupler		Made		1
	Hopper -Top Inner Solid Square		Made		1
	Hopper -Top Outer Solid Square		Made		1
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	Adjustable Vertical Clamp		Printed	stl, step	1
	Arduino Mega Mount Back		Printed		1
	Arduino Mega Mount Front		Printed		1
	Arduino Mega Mount Retainer		Printed		1
	Auger Gear Spacer - Thick		Printed	stl, step	1
	Auger Gear Spacer - Thin		Printed	stl, step	1
	Bearing Mount		Printed	stl, step	1
	Gear Blank		Printed		1
	Gear Blank		Printed		1
	Guide Wheel		Printed	stl, step	1
	Hopper - Electronics Standoff		Printed		8
	LCD Spacers		Printed		6
	Outfeed Filament Guide		Printed	stl, step	2
	Outfeed Motor Mount		Printed	stl, step	1
	Thumb Nut 1-4 in Large		Printed	stl, step	1
	Fan 60mm		Purchased		1
	90190A148		Purchased		38
	90751A117		Purchased		4
	91247A552		Purchased		6
	91280A152		Purchased		6
	91292A116		Purchased		8
	91828A231		Purchased		14
	93475A230		Purchased		32
	Hex bolt 1-4 in by 1-1-2 in long		Purchased	step	4
	Hex Bolt 1-4 in by 1-1-4 in long		Purchased	step	3
	Hex Bolt 1-4 in by 2 in long		Purchased	step	3
	Hex Bolt 1-4 in by 3-1-2 in long		Purchased	step	1
	Hex Bolt 1-4 in by 4 in long		Purchased	step	2
	M3 Rod		Purchased		4
	Nut 1-4 in		Purchased	step	14
	Nut M3		Purchased	step	39
	Nut M8		Purchased	step	5
	Nyloc Nut M8		Purchased	step	1
	Nylock Nut 1-4 in		Purchased	step	1
	Socket Cap Screw M3 45 mm long		Purchased	step	2
	Socket Cap Screw M3 by 10 mm long		Purchased	step	8
	Socket Cap Screw M3 by 16 mm long		Purchased	step	11
	Socket Cap Screw M3 by 20 mm long		Purchased	step	6
	Socket Cap Screw M3 by 25 mm long		Purchased	step	4
	Socket Cap Screw M3 by 35 mm Long		Purchased		8
	Tap Bolt 1-2 in by 4 in long		Purchased	step	8
	Washer 1-4 in		Purchased	step	35
	Washer 3-8 in SAE		Purchased	step	4
	Washer M3		Purchased	step	61
	Washer M8		Purchased	step	6
	C Clamp 3 in		Purchased	step	3
	Hopper - Heater and Fan		Purchased		1

Materials included in Kit

Name	Description	Source	Files	Qty
92865A757	Can be a bit difficult to find. Could be made on lathe.	Made		1
Auger Gear Shaft		Made	step, drawing	1
Barrel	Make from 0.5 in ID DOM steel	Made	step, drawing	1
Bottom Plate	Make from 1/4"x5" flat bar steel	Made	step, drawing	1
Breaker Plate	Make from 1/2 in aluminium bar	Made	step	1
Cooling Tube	Make from 3/8 in OD 1/4in ID brass tube	Made	step, drawing	1
Feed Throat	Make from 0.5 ID DOM Steel	Made	step, drawing	1
Flange		Made		1
Heater Zone 3	Make from fiberglass insulated nichrome wire.	Made	step	1
Heater Zone 4	Make from fiberglass insulated nichrome wire.	Made	step	1
Heater Zone 5	Make from fiberglass insulated nichrome wire.	Made	step	1
Hopper - Air Inlet		Made		1
Hopper - Blast Gate Slide		Made		1
Hopper - Electronics Board		Made		1
Hopper - Feed Throat Clamp		Made		2
Hopper - Heater Coupler		Made		1
Hopper - Outlet		Made		1
Nozzle	make from 1/2 in brass rod	Made	step, drawing	1
Thunderboard		Made		1
Top Plate	Make from 1/4"x5" flat bar, steel	Made	step, drawing	1
90273A245		Purchased		4
90273A537		Purchased		4
90473A223		Purchased		12
90473A223		Purchased		24
91247A636		Purchased		2
91390A114		Purchased		3
92865A362		Purchased		4
98023A030		Purchased		4
Arduino Nano		Purchased		1
ArduinoMega		Purchased		1
Bearing 608ZZ		Purchased	step	6
Flange Bushing 1-2 in ID x 3-4 in OD x 1-2 in long		Purchased	step	2
Fuse Holder		Purchased		1
Heating Tape 1-2 in x 24 in 104 watt	briskheat.com BIH051020L or BIH052020L depending on voltage	Purchased	step	2
keypad-16KeyMembrane1		Purchased		1
LCD 2004		Purchased		1
Merchant Coupling 1-2 in	This type of coupling has straight (NOT TAPERED!) threads all the way through.	Purchased	step	1
Nut 5-16 in		Purchased	step	4
Pipe Hanger 1 in	Also known as a "split ring hanger".	Purchased	step	2
Pipe Insulation - High Temp	High temp insulation e.g Owens Corning	Purchased		1
Pololu A4988		Purchased		1
Power Supply 12V		Purchased		1
Power Supply 12V 30A		Purchased		1
Rotary Encoder		Purchased		1
Ship Auger 1-2 in by 18 in long	WoodOwl.com recommended for larger 7/16 in shank size.	Purchased	step	1
Skateboard Wheel		Purchased	step	2
Socket 7-16 in	Pick size to fit auger shank. 3/8 in drive.	Purchased	step	1
Socket Cap Screw 5-16 in x 1-1-4 in		Purchased	step	4
Speed Nut - 1-4 in		Purchased		4
Speed Nut - No 8		Purchased		4
SSR 10A		Purchased		3
Stepper Driver Break Out Board		Purchased		1
Stepper Driver DQ2722MA		Purchased		1
Stepper Motor NEMA 17		Purchased	step	1
Stepper Motor Nema 42 4120 oz-in	Available with driver here: http://www.longs-motor.com/	Purchased	step	1
switch		Purchased		2
Thermistor		Purchased	step	5
Washer 1-2 in		Purchased	step	10
Wire Clamp		Purchased		5