Robotics & Engineering - Week of 09/22/25
I began the week by trying to start a print on one of the Fusion 3 3D printers at school, but the extruder ended getting totally jammed up and broke some of the structural plastic pieces over-night while I left it going.
Considering that the PLA that the extruder parts were printed in were already old and brittle, when the PLA got snagged on something, the plastic was the first to go.
After removing a ton of long bolts that held everything together in mysterious ways, I was able to get everything apart. Once this happened, I took the plastic apart, but I found that it was not possible to repair it without reprinting the whole part due to the significant damage caused.
Luckily, we have a secondary (broken) Fusion 3 Printer that I was able to harvest the extruder driver from, and I simply dropped it in place of the original one.
Ultimately, this didn’t work, and after a few hundred layers of printing, the nozzle clogged and the print got all strung together.
After this, I continued work on the golf cart battery system.
The copper bus bars came in so we drilled them out.
This worked pretty well, as we cut the 1/4 inch copper bars into 2 inch sections with the help of metal fab.
We quickly realized we needed to sand the bus bars’ corners down in order to prevent dangerous short circuits across the battery’s terminals.
After the tedious process of sanding, Jonas and I assembled the battery terminals together to create the battery pack. With a grand total of 76 volts, it checked out fine.
Next week, I will be putting in the BMS system and configuring it to work with the 24s battery!
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