Falcon 3D · 2017 – 2020

CoreXY 3D printers

A series of FDM printers designed and built from scratch

480 mm: Travel on every axis (Falcon HULK)

Role: Founder & CEO
Organization: Falcon 3D
Period: 2017 – 2020
Tools and methods: SolidWorks
FDM printer design
CoreXY
Large-format printing

A series of FDM 3D printers designed and built from scratch, from my first self-built machine in sophomore year to Falcon HULK, a 480 mm CoreXY printer for high-volume, large-format production.

The progression

I built my first printer in my sophomore year and kept iterating. Each generation improved frame rigidity and build volume.

Falcon HULK

A CoreXY printer with 480 mm of travel on every axis, built for high-volume, large-format production printing.

Black enclosed printer with a touchscreen — Fig. 1. Enclosed printer with touchscreen control

Linear rails, extrusions, motors and brackets laid out before assembly — Fig. 2. A printer's parts before assembly

Printer electronics bay with power supply, controller boards and Raspberry Pi — Fig. 3. Electronics bay

Fig. 4. Inside a production machine

White parts printing on a glass bed — Fig. 5. Printing production parts

A large tray printing inside a large-format printer, with a cable chain on the gantry — Fig. 6. A large tray printing on a large-format machine

A cube-frame printer with a blue-lit enclosure — Fig. 7. An earlier cube-frame printer

Open-frame 3D printer with an aluminum extrusion frame, glass bed and exposed wiring — Fig. 8. An open-frame printer in development at Falcon 3D

A red printer frame with an automated arm for removing prints — Fig. 9. Automated print-ejection system