In case anyone is curious, I worked up a list of materials and what I paid for them (to the best of my recollection) or what they would cost now.
Materials: About $500-$600 total
It depends on how much you have to pay for shipping and what you can scrounge up for free. (I did it for about $375 with scavenged/recycled materials and some leftover stuff from previous projects). Since I spread out the spending over 2 years it really didn't seem like much at the time. The projector was the single most expensive item but if you watch eBay you can usually find one for a reasonable price. If you want to have a build envelope larger than 4x6 you might want to look into a higher resolution projector (with a higher price tag).
- Projector – Mitsubishi XD430U (1024x768, 230W UHP bulb) $150 from eBay
- 1 Stepper motor for Z axis – Scavenged from old equipment (about $10 surplus from allelectronics.com)
- 1 Stepper motor for shutter (optional) – also scavenged from old equipment (about $10 surplus from allelectronics.com)
- 2 axis bipolar stepper driver – I had one, (it was about $40 from eBay a few years ago) obviously if you only use 1 stepper you can get away with the cheaper 1 axis controller
- AC relay board - to control the air pump. $18 from cnc4pc.com
- Basic Breakout board – Had one of these too, ($10 from cnc4pc.com)
- 24V Power supply – Had an extra one. ($20 from eBay) or convert a pc supply.
- Aquarium air pump - $14 from Walmart
- Switches – assorted mechanical and optical, had a bunch of these scavenged from old equipment.
- Parallel printer cable and assorted wire from my Box ‘O Stuff
Mechanical:DIY Z axis :
- Scrap MDF / Pine 2x4 – Free?
- 1” Steel angle bar stock – about $16 from Home Depot
- 1” Aluminum angle bar stock – Had some from a previous project (about $5 from Home Depot)
- 8 roller skate bearings - $5 from eBay
- Assorted Nuts, Bolts, Washers and Corner braces – about $10 from Home Depot
- Acme threaded rod - $19/3ft from McMaster.com (I only used 16” so really $9.50)
- Coupler – Had one of these too ($15 from dumpstercnc.com)
- DIY leadnut – You can make one for next to nothing, if you have the Delrin, or buy one (about $20)
- HDPE Cutting board material 1” - $17 from onlinemetals.com. I could probably have used MDF if I wanted to go extra cheap.
- HDPE cutting board material ½” - $9 from onlinemetals.com. I could probably have used MDF if I wanted to go extra cheap.
- 2 Hinges – medium/small brass from Lowes $4
- Glass – $10 for a 12”x12” piece of double thick (5mm) glass from Delphiglass.com. (I cut 3 windows from this so I have a few extras ready for quick replacement)
- Bolts, threaded inserts, washers – about $8 from Home Depot
- Sylgard 184 – $50 / .5 Kg from eBay. That’s probably enough to coat 20 or more 4x6 pieces. It’s really a consumable but I’ll include it in the build cost.
- More scrap wood
- HDPE scrap from the vat construction
- Cheap cutting board - 3/8" thick about $3 from Walmart
- Aluminum angle left over from the z axis
- ¼” 4x6 Aluminum plate – about $5 from onlinemetals.com
- More corner braces - $5 from Home Depot. I could have cut these from scrap wood and glued them in place but I got lazy.
- Scrap MDF, Plywood, Melamine shelving
- Scrap steel for projector mounts and front supports – from an old server rack mount
- Even more corner braces - $5 from Home Depot
- Red Plexiglas for door and projector shutter (optional but nice) - $30 from local supplier
- Drawer pull, hinges and magnetic cabinet latch – Had these in my parts box. (About $7 from Home Depot)
- Misc screws/bolts – from workbench
I'm already thinking of ways to improve/simplify the design and will undoubtedly recycle most of the parts for the MkII