It hasn't caused a print failure or much delay but twice now the CR-10s5 has incorrectly decided that it was out of filament.

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The correct saw blades and an angle grinder made quick work of the Alto base frame's metal tabs that were left over from the bending operation. This is the first time I've assembled full sized printed parts with their metal frame and friends, it's solid af! The last pic shows the bottom of one of the arms. When secured, the tip of the metal arm will rest against the inside front of the plastic arm.

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This morning I started the first full size printed part for an Alto's monitor case. Even with a 1mm nozzle and 0.7mm layer height it's estimated to take ~12 hours. I could probably squeeze a bit more speed out of the CR10s5 but the cycle time is slow for testing the cascading effect of speed changes on large (for FDM) parts. If I had more space then I'd throw money at the problem by bringing in two more of these printers, but here we are.

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Here's a rough* print of an Alto display base, set on my desk to give you a sense of scale. Tomorrow I plan to grind the bend tabs off of the inner metal frame and weld on the swivel hemisphere so that I can fit the print to the metal.
* no chamfers, sanding, paint, etc

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I'm pretty happy with this layout for monitoring a long print. provides the webcam stream and I created a local web page that shows it at 100% of the page. On the right is the "GCode View" which renders the current layer and the head position. (the print is a 5x7 Gridfinity "weighted baseplate" using a 1mm nozzle for speed and that bumpy aesthetic)

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I've settled into this layout for on an ultrawide display. I usually open two files: one for parts and one for an assembly. So far it's working well.

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I received a shipment of LCD panels and driver boards which were thankfully not damaged by whatever poked a hole through three layers of cardboard and a thick layer of foam. I ordered a few extra for spare parts and maybe to extend my ultrawide display to the left and right. (I ❤️ pixels)

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My laser cut and bent parts from OSH Cut arrived and I've started printing slices of models from CAD to measure fitment and to test a chonky 1mm nozzle. Also, I rediscovered my fuzzy wrist and head bands which are great for sweat in a shop heated by the CR-10s5.

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I truly enjoy artbreeder as a sort of daily meditation on whatever phrase pops into my head. Today's was "1970s computer monitor". (marked sensitive because algorithmic images creep out some folks)
collage.artbreeder.com/

The quarter scale Alto display has a working swivel and and has jumped up another cuteness shell. Once it's further primed and painted I may die of squeeeeeeeeee.

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Today I printed 1:4 scale versions of some of the Alto display case and frame. The floppy part on the upper right is floppy because the full size version is 0.1" thick steel so when scaled down that's not much material. The first coat of primer is drying and eventually I'll give them a nice coat of beige.

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Based on the metal parts I received from OSH Cut I've made a few changes. The base frame will now peek just a little bit below the level of the surrounding case to provide more durability during rough moves when the weight might fall on the base instead of the rubber feet. The frame won't be visible during regular use. I also lowered the wings on the upper display frame so that it can be bent by OSH Cut's beefy hydraulic press. I may make support parts to re-strongify the display.

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I moved the absolute unit of a printer and needed to re-level it. I have learned that big beds needs to be at printing temperature when leveling because the heat causes shifting. Leveling cold can take care of large scale warp but for precision it's level hot or go home. Also, I'm using the Miranda method of bed adhesion (clean with soap and water, then never ever ever ever ever touch it) and so far it's a success.

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Printing test coupons for finishing tests: surface roughness, color, texture, etc.

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Test parts from OSH Cut arrived. This is the inner frame of the base. I will take an edge grinder to the front legs to take off the horizontal tabs that were required for the bends and then I'll stick weld a steel hemisphere over the hole. The display will have a cylinder that swivels on the sphere.

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I drew up the bezel in which is the last major external element of the Alto. There are still a number of internal features like fasteners and the LCD fixture as well as a few tweaks to the curves to more closely match the curvaceous cases.

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It's not in scope for this project but once I've delivered the Alto display replicas I'll be tempted to replicate the custom Honeywell keyboard that slips into the front cutout of the base. Along with the chording keys and mouse, it would complete the user-facing aspects of the Alto. The Dorado CPU could also drive an Alto display when necessary.

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Here are the labels attached to the back panel of the Alto model II display that I'm using as reference. It was manufactured for PARC in St. Paul, Minnesota by Ball Electronic Display Division in 1979.

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