Build Phases
14-week build timeline for the Colex Forge conversion project.
Measurements & 3D Scanning
Scan the Colex tool bay, gantry uprights, bed surface, and all interface points using the Creality Raptor Pro scanner to create precise 3D models for CAD design.
CAD Design & DXF Generation
Design all custom mounting brackets, Z-extension columns, tool head adapters, and heated bed frames in Fusion 360. Generate DXF files for laser cutting.
Laser-Cut Structural Parts
Cut all mounting plates, gussets, brackets, and structural adapters on the laser cutter from steel and aluminum sheet stock.
Z-Extension Column Install
Raise the gantry bridge by installing 4080 aluminum extrusion columns between the existing uprights, giving 24+ inches of Z clearance for tall prints.
CF Tool Head Build
Assemble the carbon fiber tool head: E3D Volcano hotend with DiamondBack 0.8mm hardened nozzle and Bondtech BMG extruder, mounted to the Colex tool bay adapter.
CMYK Tool Head Build
Assemble the 4-in-1 CMYK color mixing tool head using the Zonestar system with quad extruder motors and mixing nozzle for full-color PLA printing.
Heated Bed Zones
Install silicone heater pads in zones across the large bed, with SSR relays and PID controllers for independent temperature control of each zone.
Thermal Testing & Insulation
Test bed temperature uniformity across all zones, add insulation, and build a partial enclosure for heat retention during CF-Nylon printing.
WinCNC Axis Mapping
Configure WinCNC to map the extruder to the A-axis and auxiliary outputs to heater controls, transforming the CNC controller into a 3D print controller.
G-Code Post-Processor
Build a Python G-code translator that converts standard slicer output into WinCNC-compatible commands, then run the first test print.
CMYK Color Calibration
Calibrate the 4-in-1 mixing hotend color ratios, tune purge sequences, and create color profiles for the CMYK system.
AI Camera & Scanner Setup
Configure the Colex's gantry-mounted camera and the Creality Raptor Pro scanner for real-time print monitoring, defect detection, and in-process dimensional verification.
Full System Integration Test
Run comprehensive multi-material test prints combining CF extrusion, CMYK color, heated bed zones, AI monitoring, and real-time scanning for full system validation.
Documentation & Publication
Write final build procedures, update the Colex Forge website with results, create maintenance guides, and publish the project documentation.