Using the vertical build method the above assembly was designed. It consists of right and left Main @ Intermediate Driver Section (MIDS) frames, the two frame spacers in proper position and the two brake hangers in position. The overall assembly is 2 3/4" wide, 4 3/4" long and 1 1/2" high. By building it as an assembly it becomes an integrated whole and does not require any jigs or fixtures to make it square and true while applying glue. This kind of assembly was contemplated originally, and temporarily abandoned when horizontal builds of this length could not be make successfully.
As was done for the single side frame member vertical build the Axon software for the BFB-3000 3D printer defined a large array of support material around the part. The part was built in black ABS with green ABS raft and supports. You can just make out one of cross braces between the vertical side frames. Also, the two brake hangers that are located between the intermediate and main drivers are visible midway up the outside of the frames.
The bottoms of the frames have the frame keeper attachment features and the pilot holes for the small bolts that will be used to hold the keepers in place. Each keeper provides continuity across the bottom of the frame below the slots where the wheel bearings are located.
This view of the printed assembly prior to removal of the green support material shows the top or front of this portion of the frame and the cross brace that is located just after the intermediate driver slots. Another cross brace is located following the main driver slots which are at the bottom of the print assembly, or more rearward on the frame. The driver order is Front, Intermediate, Main and Back. The Front and Back are identical while the Intermediate and Main differ with larger crank axles and in the case of the Main a larger wheel axle and bearing assembly.
The next step will be to remove the green support and raft material hopefully avoiding damage to the black MIDS frame assembly contained within.
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