This instructable is for making an electric coffee maker. Nearly all components are from readymade diy parts & materials, so if any part ever breaks, you can repair or replace it. The parts from the casing were printed using Filabot filament, which is made out of recycled plastic. Other parts are made by casting local waste aluminum (such as cans, aluminum foil and chips from cnc milling aluminum). There is no glue used so you can always disassemble and reuse/recycle every part. So when I would ever get tired of coffee, I can send back my 3D-printed parts to Filabot (they have a recycling service) and I can remelt and reuse the aluminum for new projects. I tried using as much locally produced parts as possible and using as many components as possible which are not related to a specific model or product.
I made everything by learning from online tutorials, by using as much scrap material as possible and by utilizing the local fablab: Fablab Genk.
You will need a 3D-printer (I used the Makerbot Replicator 2X from Fablab Genk for the 3D-printed parts), a setup for casting aluminum and the right tools for assembling the internal components to each other and to the casing.
NOTE: This is a prototype, so some components or parts might have to be optimized. If there are any suggestions for improvement or any mistakes in my instructable, please let me know so I (or you) can adjust it.
Please keep all safety aspects in consideration. Electricity can be dangerous so double check everything before testing. I'm not responsible if anything goes wrong. Never leave the coffee maker running alone. Better be safe than sorry. :-)
(English is not my native language, so excuse me for any spelling mistakes or wrong use of certain words.)
There's quit some internal parts you will need. I found all the parts on the internet, but you might check your local diystore if you can find some parts there.
These are the internal parts you will need:
- Funnel (top diameter around 100mm)
- Aluminum plate (for small parts, see next steps)
- Thermostat (KSD301 105°C)
- 4x M3 bolt length 6mm with Phillips or slotted head
- 4x M3 nut
- Temperature fuse
- 2x Parallel connector
- 1m flexible silicon wire 1,5mm
- Ring connector for 1,5mm wire (M3 hole)
- 1m Silicone hose 10mm inner diameter
- 1m Silicone hose 6mm inner diameter
- Heat resistant tube
- 7x M4 bolt length 12mm for embossing with Phillips or slotted head
- 2x M4 bolt length 6mm for embossing with Phillips or slotted head
- 2x M4 bolt length 30mm with Phillips or slotted head
- 13x M4 nut
- Rocker switch (minimum 6A)
- 4x Hose clamp 13,7mm to 15,3mm
- 2x Hose clamp 10.8mm to 12,3mm
- Grounded chord and plug for 220-250V
- 3x Faston angle connector 4.8 width
- 2x Faston connector straight (6mm width, depending on the connectors on your thermostat)
- Thermal paste (1 gram)
- Heat-shrink tubing 6mm to 2mm
- Heating element
- One way valve for water which fits the 10mm silicon hose
- Plastic cup (from paint gun, so make sure it's new and clean)
I ordered my parts from a German company called 'Conrad'. They supply many countries in Europe, so you can find the order number of most of the parts on this list:
On Conrad you can find everything except these:
You will have to order this from a supplier for replacement components. I ordered mine from Servilux (order nr 141709)
If your order somewhere else you have to make sure it's similar to the one on the picture in order to complete the coffee maker.
- Plastic cup 600cc
This will serve as the water tank. Depending on where you order them they might have a different thread. So if possible order one with a thread where the hose fits around, otherwise you also need an adapter. This so you can make a transition from the thread of the cup to an outer diameter between 10mm and 13mm.
I ordered mine from nonpaintstore.nl (part nr 4213505). It's not cheap but it has the right fitting on it for the silicon hose.