Base Plate

To assemble a free-flyer, we will start with the bottom plate. This plate provides support for the remaining layers and contains the pneumatic components for air-supply, regulation, as well as air bearings for frictionless motion. The final assembly can be seen in the 3D model below.

Polycarbonate Plate

The baseplate is composed of a single 8 mm thick polycarbonate plate - item 0101 in the Bill of Materials. The diameter of the plate is 400mm and it is recommended to be cut using a CNC waterjet. The DXF file for the plate can be downloaded here, and the end result can be seen in the 3D model below.

Air Bearings

With the plate cut, we are ready to start attaching the air bearings. These bearings are used to provide a frictionless motion to the platform. The bearings are attached to the plate using the provided mounting screws, nuts and washers - items 0103 and 0104. In the center of the plate, on the underside, we should also attach an X-connecting piece to allow for the air supply to reach the bearings - item 0214. Then, connect the air bearings to the X-connector using 6mm tubing - item 0210. A further length of tubing runs from the X-connector up to the topside of the plate, where it connects to the air bearings regulator - item 0206 - in the step below. The 3D model below shows only the placement of the bearings and X-connector; the tubing runs and regulator (0206) not depicted.

NOTE

After installation, the air bearings shall be protected from damage and kept on clean surfaces. We recommend to use the provided boxes for storage and transportation.

Bottle Supports and Regulators

At this stage, we are ready to install the bottle supports, thruster pressure regulator, and air bearings regulator. The first step is to print all the 3D supports in here. The parts are then attached to the plate using M4x20 mm screws, nuts and washers according to the 3D model below. The items used in this step are 0206, 0207, 0208. The air bearings regulator - item 0206 - takes the tubing run coming up from the X-connector beneath the plate. For the thruster pressure regulator - item 0207 - screw a push-in fitting - item 0208 - into the inlet and outlet ports and tighten each with a wrench before connecting any tubing; the G1/4 thread seals against the port face, and leaving these hand-tight is a common source of air leaks. The 6mm tubing then presses into the fittings by hand.

Bottles and in-line Regulators

Next, we are ready to test the bottles’ mounting and install all in-line regulators. Start by taking one bottle (item 0201) and attach to it the first (item 0202) and second (item 0203) regulators. Then, at the end of the last regulator, make sure to use the provided Festo-compatible fitting. Lastly, attach the 3D print part that secures the regulators to the bottle next holder.

Aluminium Profiles

Almost at the last step, we are now ready to install the supporting aluminium profiles. These profiles are used to provide structural support to the platform and are attached to the plate using the provided angle brackets and T-slot nuts. The items used in this step are 0102, 0105, 0106. M4×8 mm screws and nuts are used to secure these items to the locations shown in the 3D model below. Attach the angle brackets - item 0105 - to the profiles first, working on a level surface: leave the T-slot nuts loose enough to slide, square everything up, then tighten evenly. Brackets set slightly off-square here will leave the profiles uneven once mounted to the polycarbonate plate.

Manifold

Manifold - Assembly

At this point, we are ready to assemble the manifold plate that will direct the air from from the bottles to the air bearings and actuators. The STL files used in this step can be found below.

Manifold - Baseplate

First, start by 3D printing the baseplate.

Manifold - Supports

Then, we attach the 3D printed supports for the valves and tubing using M3x8 mm screws and nuts.

Manifold - Valves, T-pieces and Tubing

Next, we attach the valves and T-pieces to the manifold plate using the valve supports. Note that the valves have a rectangle extrusion that will be used to attach to the support, ensuring correct orientation and alignment.

Lastly, we can add the tubing to the manifold.

Pneumatic Plate - Attached

The last component to attach to the baseplate is the manifold plate. This plate is used to provide a mounting location for the valves that direct the airflow. The aluminium profiles are then attached to the base plate using M4x20 mm screws T-slot nuts - item 0106. Each aluminum profile should have a length of 23cm. Using 6mm tubing (item 0210), connect the bottles to the pneumatic plate according to the diagram. Print the provided 3D parts and assemble them according to the 3D model below.