FoldaRap Buyers Guide

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FoldaRap Documentation

This project was for myself, as I need/want a RepRap that's easy to carry around and for the challenge of making a folding 3d-printer. But I believe in open-source and sharing and all the revolution behind that. Thus I try to well document it, in case others want to make one; to acknowledge all the things we own to those who went before, and to encourage those who come after to do the same.

On a more long-term view, I didn't planned to create a company out of it, I hoped to see it grow on itself in the wild, just by indicating how to source it, because I have more fun in designing stuff than marketing it. Nonetheless I may try to sell few beta-test kits (bulk ordering is good for prices), eventually via a crowdfunding campaign or by request, maybe with the help of my hackerspace. Just for the experience of it and to say I can push a project to that point :D (edit : Done !, again, and it finally gave birth to Edge)

(almost all the projects I did during my design studies could have done something, but I never found the time for that and they ended sleeping in their drawing books which is sad; while now I have taken the habit to publish everything, even an old one sometimes).

"Ideas are like living things and breed happily in an open-source context" as I like to think ^^ (on the same spirit I like this comment from User:Adrianbowyer)

Bill Of Material (BOM)

Total end cost for 1 machine : ~500-600€ when you include all taxes and shipping costs. I suggest you to make group orders with friends and always try to source locally, or now for almost the same price I can make a kit for you.

Hardware

Foldarap hardware-kit.jpg

5  20x20mm beam 6mm slot 200mm - Motedis or see Aluminium_profile_Suppliers
6  20x20mm beam 6mm slot 300mm
54 M4 T-nut for 6mm slot - Motedis
54 m4x8 round head bolt - Fix'n Vis Round Head Bolt
4  m5 nylon nut / Z-rod (4) [1]
3  m3 nylock nut / bed leveling (3) nylock nut
15 m3 nut / hinges (2), bed (3), Y-belt-clamp (2), extruder (2), plug (2), psu (4) - Fix'n Vis Nuts
14 m3x8 bolt / Z-motors (4), Y-motor (2), psu (2), male plug (2), board-mount (2), hotend (2) - Fix'n Vis Bolts
8  m3x10 bolt / hotend (4), y-belt-clamp (2), extruder (2)
1  m3x16 bolt / extruder (1)
4  m3x20 bolt / hinges (2), Y-idler (1), extruder (1)
4  m3x25 bolt / hotend-holder (2), fan-holder (1), (extruder 1)
4  m3x30 bolt / x-slider (4)
3  m3x30 countersunk bolt / bed (3)
2  m3x35 / extruder (2)
2  230mm threaded rod m5 - Fix'n Vis
2  extruder spring - RS751483 or see Springs
3  bed spring - RS 751455 or RS 751607
1m spiral wrapping band for tidying the wires - RS227874
7  6,35mm ferule - Radiospare to crimp the cable for the plug and the switch
2  5mm to 5mm flexible coupling
3  linear bearing, LM6UU or if you can Igus RJMP-01-06 - See Bearing
2  300mm smooth rod 6mm - (can be salvaged from usual scanners and printers) or see Smooth rod
5  603zz bearings / X-slider (2), Y-idler (2), extruder-idler (1)  - See Bearing
1  250mm T2.5 belt 5mm wide - RepRapWorld or see Belts_and_Pulleys
1  600mm T2.5 belt 5-6mm wide
2  T2.5 pulleys - Belts_and_Pulleys
330mm PTFE Tubing for bowden extruder (2mm inner diam. and 3mm outer) - See Bowden
2  Pneumatic fittings for 3mm tubing, with M5 thread - See Bowden or emakershop / I'm using the MA12-03-M5 but others can work
1  direct drive gear - Maritime-models (see Drive-gear)
1  roll of kapton - See Kapton Tape#Vendors
20 zip-ties

Electronic

5 nema14 stepper motors - [2]
3 miniature microswitch endstop 20mm - [3]
1 standard male plug IEC C13 C14 - RS 5392045
1 standard female cable - EU/C13 - UK RS6266739 / US RS7316163
1 big blue switch - RS 5287858
1 RepRappro Hotend - emaker
1 40x40mm heatsink - RS 6744769 to make a more compact hotend
1-2 small fan (40 x 40 x 10 mm), for the hotend (can be bought with one) and the extruder motor - RepRapWorld or see Fan
1 100k thermistors - Mouser
1m of 18AWG wire (200mm red, 200m black, 150mm green) for the switch/plug/psu - Read also WiresAndConnectors
10m of 26AWG (3.6m red, 3.2m green, 2.0m blue) for the sensors and fans
1 Minitronic board [4]
1 USB cable A to B [5]
1 12V power supply : 5A (cold bed) or 10A or [6] (for heated bed)

or

1 Azteeg_X1 board - [7] + 4 drivers
1 usb to mini-usb cable - [8]
1 12V power supply : 10A

or

1 Rumba + 6 stepper drivers
1 usb to mini-usb cable
1 12V power supply : 20A (RS 7066316 100*150*35mm)

Heated-Bed

For the aluminium heated bed add :

1 aluminium bed plate (4mm thick)
1 100k thermistors - Mouser
2 ferule 0,5mm²
1 peltier element 12708 (40x40mm is enough) - ebay

Laser cut parts

See the github repo and eMakerShop, you can have them from Ponoko too

The bed can also be made of acrylic in case of a non-heated bed.

FoldaRap bed-plate 1.1.jpg

Printed parts (total : 21)

See also the github repo

Other

Padded suitcase

Maintenance

  • 0.3mm drill bit [9] (or 0.5mm, depending of the nozzle)

How to replicate a FoldaRap !

If you can print your own parts it will take ~400gr and 22h at ~30% infill.

Material

The parts that act as sliders on the aluminium extrusions (x-slider, z-sliders) will work better if printed in PLA or other low friction plastic. You can print the other parts in ABS or what you want.

Recommended settings

  • Nozzle diameter of reference : 0,5 mm
  • Layer height : 0,25mm
  • Infill : 30-35% hexagonal/honeycomb
  • It is advised to have a well calibrated machine (+/- 0.05mm on measured parts) : http://forums.reprap.org/read.php?282,159683

30percenthexainfill.jpg25percent-rectilinear-infill slicer.jpg

Foldarap precision-needed.jpgReprapworld-black-print2.jpgReprapworld-black-print.jpg

I recorded this little video where I'm playing with some parts freshly printed, to show what to expect about the tight tolerances.

<videoflash>rRXyc5I8yfo</videoflash>

The part that slide under it's own weight (16gr) have been slided back and forth a few time.

Fully assembled machines

Not yet.

Partial or complete kit

Webshops

Printed parts

Misc.

  • A draft BOM is on Kitbom
  • My spreadsheet is roughly the same as the following lists but a little outdated.


FoldaRapMendel Bom

Foldarap-Mendel 00.jpg

1 underplate
6 300 mm
6 400 mm
50 M4x8
8 M4x12 (hinges)
2 M4x16 (hinges)