PANDA 2- DUST SEPARATION VACUUM CLEANER (100% SUPPORT-FREE )

https://www.youtube.com/watch?v=FoX1BfXnuIw

Yes, it is 100% support free for every part of the assembly, it is a thoughtful and considerate project that does not require you to get into any extra works and time getting rid of supports which eventually leads to those ugly marks on your product. Then what's so special about this project other than my previous Panda robotic cleaner, well I bet that big acrylic transparent pipe had caught your attention at first place wasn't, Yes, the vacuum cleaner segregates large and small particles to different chambers respectively just like how Dyson's cyclone technology does. Although Panda 2 doesn't use Cyclone , there is an alternative method to achieve the result. So let's take a close look of Panda 2 before we get going through the making process.

"The project is composed of 23 support-free printing parts, simply just print them out and assemble your very own vacuum cleaner. It is as easy as that."

IE The idea of debris segregation and product design is totally original from scratch to the final, this includes mechanical to cosmetic, a numerous testing parts had been printed out in the past 5 months just to make sure each part is perfectly fitted to one another, trials and errors and proof of the final workable result. After all those hard working efforts, I hope you will enjoy the following instructables and the pleasure of making your own unique handheld vacuum cleaner.
If you find it a valuable project and like the instructable, please vote for Panda 2 Thank you.

Step 1: HOW DOES IT WORK?

Panda 2 is a power handheld vacuum cleaner that uses 12V DC motor to generate 48 watts suction force.

So how does it segregate large and small particles. Let's take a close look of the top-sectioned photo and will have better understanding of it. As the picture shows. colored arrows indicates the direction of air, as the air flows through the head, because large debris's mass. its travelling speed maintains its linear trajectory, so large debris is been thrown to the front chamber (purple arrows) and trapped. At the same time, the diverged blue arrows that carries small particles flow through the side 2 tunnels until it reaches the rear chamber where there are 2 sponges (yellow block) serve as filter that filter out all small particles. Once the air passes through the yellow section (red arrow), it reaches the impeller's chamber where clean air is been forced out via venting holes.

Step 2: Modular Design & Other Features

Modular Design

Panda 2 is composed with 3 modular parts as the photo shows 1) Body 2) Dust collector 3) Head, each of them can be easily seperated, and replaced under circumstances where one module is broken, or can be customized to different color for different mood.

Other Features

1) Head is designed to be rotatable, it swivels at a maximum of 20 degrees, It is ergonomically designed and it is super easy to be used by anyone. (File been given is not swivel head version.)
2) A locking mechanism (plug and twist) allows you to easily attach and detach each module.
Good for replacement and cleaning of each module.(And it's air tight.)
3) Lighter weight - lighter weight than comparative product such as Black&Decker Dustbuster. 10%infill produces 730g as opposed to Dustbuster 760g.
4) Swappable head- Swap the head to different kinds for different usage scenario (carpet,marble ground, office/car ).
5) Ergonomic handle design for better gripping.

Step 3: What to Gather

Components that you need to purchase are:

1) Johnson 570 12V DC motor (Panda's casing is designed specially for Johnson570, other model or brand of motor won't work.)

2) Rocker switch

3) Acrylic pipe 8cm diameter (Thickness:3mm) Cut to 9cm length. !**Thickness need to be exact3mm else it will not fit.

4) 5.5mmx2.5mm female power cable

5) 12x M2.5 brass nut

6) 11x M2.5 screw 1M2.5x9 screw

7) 120AC- 12V DC adapter (4a above, below 4a won't work)

8) 5.5mmx2.5mm Power extension cable (optional), male and female at each end (length that suits your need)

9) Super glue "Gel" (Do not buy liquid form)

10) Soldering iron

11) Glue gun

12) Filter sponge

Step 4: PRINTER SETTING

Please download the three zip files: 1) Body Module.zip 2) Dust Collector Module.zip 3) Head Module.Zip

There are total 24 parts (including the jig)

I use Makerbot 2x replicator,

Please follow the below setting to print all parts.

Setting

nozzle temperature: 245C

Platform temperature: 150C

Infill: 10% (below shows the time estimated to print 10% infill)

No of shells: 2

Layer Height: 0.2mm

check Raft but not support.

If you are not clear about which side is the raft side, please refer to the pictures, red surface is the raft side.

Without support option box checked,some parts will have overhang, which will lead to minor defects ( filament dangling)，
simply just remove those dangles, they will not affect the performance and assembly. Eg. Photo12 shows severe distortion, it is ok, it's not affecting cosmetic or performance.

Some parts have warpage surface after raft is removed, please sandpaper the raft surface. It will make the assembly 0 gaps and looks better.

Printing time reference

BODY module:

Blade.stl (1hr) Body.stl (5hrs) HandleR(2hrs) HandleL(2hrs) Top Cover (1.5hrs) Top Cover_3 (1.5hrs) Washer (1 hr) Btm_cover(1.5hrs)

HEAD module

Head2(4hrs) 3way_1 (1hr) Head Base(2.1hrs) 3way_2(1.5hrs) Head_base_block(0.5hr) Head1(1.5hrs) Airduct (1hr)Side coverx2(1hr)
Plug(1hr)

Step 5: Let's Assemble- the Body

Photo 1-4) press heated soldering iron's tip against brass nuts to both Body.stl and HandleL.stl parts until they are fully melted into plastic.

Photo 5) place the motor into Body.stl

Photo 6) Cap Washer.stl to the top of motor (tight fit)

Photo 7) screw tight Top cover.stl to Body.stl

Photo 8) make sure impeller central hole is clear. Test fit to motor shaft before applying glue.

Photo 9-11) If the impeller can fit to motor's axle,take impeller off, then apply super glue "GEL" to a toothpick. Apply the glue to the inner wall of the impeller. Place impeller back to the axle, finally, apply more glue to the top for reinforcement,and let it dry for a while.

Photo12) Try to hook up the motor to test its rotation, fan should rotate clockwise.

photo13 14) Please hook up the wire as according to the photo for handle, there are holes for wires to go through, please beware, else handle cannot be assembled.

Photo 15 16)Wires through Btm cover, clamps two handle casings to Body.stl. Screw tighten Btm cover (3screws，beware 1 screw underneath the handle) ,and handle (5screws). and congrats, done for the body module.

ie sandpaper both surfaces of btmcover and body where they are attached to each other before assembly. This eliminates big gap due to the minor irregular surface by raft.

Step 6: Let's Assemble- the Head

The head assembly uses interlock concept (toolless for sub assemblies), this way, it is much more convenient to maintain or replace with new parts. Let's start.

Photo 1) Apply 4 brass nut to the Front base.stl with soldering iron.

Photo2) Super glue head base block.stl to the head base.(beware of the direction.)

Photo3) Glue gun the airduct.stl to the headbase. (using glue gun allows you to remove the airduct easily in the future, as well as it helps to secure the air from air leaking)

Photo 4) Screw tight Head1.stl to the head base.

Photo 5-6) Insert 3way to Head2.

Photo 7) Cap the assembly from both sides with side cap. (The side cap is tight fit and helps to fix the3way in position)

Photo 8) Insert the other 3way part to this assembly, this part will go through Head2 and the inserted 3way.

Photo 9) Use rasp to smooth and flatten the edge. (warpage from printing will affect the assembly, for better result,please rasp it)

Photo 10-11) Hook both sub assembly together, a push from the back to snap the top sub assembly to the bottom.

Photo 12) Insert the plug to secure the air duct and the full assembly.

Photo 13) Add a velcro to gain more smoothness while scrape the head against any surface.

Photo 14) If you find the head's twist and lock is too loosen, try to get something and stuck it into one of the twist hole, this will stop the head coming off while cleaning.

Congrats you finished the Head.

Step 7: Let's Assemble- Dust Collector

Photo 1) Glue Lid.stl to the acrylic pipe.

Photo 2) Grab topcover3, insert brass nut with soldering iron.

Photo 3-4) Once inserted the nut, adhesive the top cover3 with topcover2. (make sure hole to hole.)

Photo 5-6) Pre install the head, and make sure top cover's brass nut hole is perpendicular to the head. Mark it with a marker before drill a hole.(This is to ensure that screw hole is exactly on the bottom of the acrylic pipe while using the device,.)

Photo 7-8) Drill a hole with jig.stl for accuracy. And apply the screw to see if it can go through.
Photo 9-10) Apply super glue, make sure top cover's hole is in alignment with drilled hole. And screw tighten both parts.

Step 8: Let's Assemble-Filter

Photo 1) Super glue two filter parts together, beware of the direction when super glue them.
Front entry should always goes opposite orientation as the the rear circled area does. see the photo for reference.

Photo 2) Insert 2sponges .

Step 9: Finished

Congrats, you now have your own vacuum cleaner. Here are some more photos (including the prototype) to show the completed project. I hope you like this instructable. Enjoy and see you next time. ^_^