Prusa i3 Build Manual

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Revision as of 04:50, 12 February 2013 by Misan (talk | contribs) (M5 Z axis, single frame - or 300mm if you do not want it to protrude above the frame)
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Prusa i3 Documentation

Boxed style Frame Style

I3-box frame.png

In the future this page might contain a tutorial. Until then, a tutorial for the boxed frame style Prusa i3 by Kliment:

Rods

X Axis;

  • 2x 470mm 8mm smooth rod
  • 1x 20mm 8mm smooth (for extruder idler, use 8x20 threaded rod or grub screw instead as substitute)

Y Axis:

  • 2x 470mm 8mm smooth rod
  • 2x 500mm M8 threaded rod
  • 4x ~200mm M8 threaded rods

Z Axis:

  • 2x 405mm 8mm smooth rod
  • 2x ~370mm M5 threaded rod

You could play with the Z lengths to increase building height.
For this you will need longer wood cut for 4 of the 450x100mm plates; add n to both wood (450+n)x100 and all Z axis rod length)

Frame

Default is 15mm thick wood. Get something that is robust!! The thickness is mostly needed because you screw into the side of the wood!

  • 6x 450x100x15mm wood
  • 1x (450+15)x(100+(15*2))x15mm wood (for the ppl that suck at math; thats 465x130x15mm wood)

Any wood _over_ 15mm thickness will not work for the bottom plate, the Y will then be lifted from the ground.
So if you are using thicker wood for the frame, this _will_ work, but be sure to _NOT_ use thicker wood than 15mm for the bottom plate of the frame.

Single Sheet Frame Style

I3-ali-prusa.jpg

http://www.flickr.com/photos/prusajr/8107645350/in/photostream

Materials

Single plate Version Rods:

X Axis;

2x 370mm 8mm smooth 1x 20mm 8mm smooth (for extruder idler, use 8x20 threaded rod or grub screw instead as substitute)

Y Axis;

4x 205mm 8mm threaded 2x 320mm 8mm smooth 2x 345mm 10mm threaded

Z Axis;

2x 320mm 8mm smooth 2x 320mm 5mm threaded (or 300mm if you do not want it to protrude above the frame)

Rod Lengths:
http://titanpad.com/bU77NESnMC

Parts to be Purchased

BOM

http://www.ethercalc.org/wcrkzrngtw

Belt guide bearings x 2 some use 623's some use 624's the Ø4 holes can suit 624 but some modification or finding the right copy among the Githubs listed above may be required at this stage i3 rods BOM


NEMA17 steppers x 5
J-Head MkV x 1
GT2 pulleys x 2
GT2 belts x 2
(Note that MGS files in Sound's i3-underwelt branch is stl's with T2.5 belts assumed)
clear tubing (z coupling) x 2
Z drives M5 (length) x 2

Rapid Prototype Parts

DescriptionQtyImage
RP Partslocated in Prusa/single_plate folder
z-axis-top.scad1
I3-Z-axis-top.png
z-axis-bottom.scad1
I3-Z-axis-bottom.png
y-motor.scad1
I3-Y-motor.png
y-idler.scad1
I3-Y-idler.png
y-corners.scad4
I3-Y-corners.png
y-belt-holder.scad1
I3-Y-belt-holder.png
x-end-motor.scad1
I3-X-end-motor.png
x-end-idler.scad1
I3-X-end-idler.png
x-carriage.scad1
I3-x-carriage.png
magnetic-holder.scad (used for hall effect sensors / endstops)2
I3-Magnetic-holder.png
fan-mount.scad1
I3-Fan-mount.png
belt-guide.scad (suit 623 bearing)4
I3-Belt-guide.png
Extruder optionsnot complete documentation at this stage
gregs-wade.scad (in box_frame/extras folder)1 (???)
I3-Gregs-wade.png
greg-adapter.scad (in mini/extruder/greg-wade folder)1 (???)
I3-Greg-adapter.png
dual-extruder.scad (deprecated - experimental)1 (???)
I3-Dual-extruder.png
compact-extruder.scad (experimental - likely to be replaced by nema17 extruder)1 (???)
I3-Compact-extruder.png
EiNSTeiN branchmaster branch of i3 single-frame parts by EiNSTeiN: master at https://github.com/EiNSTeiN-/Prusa3/
platter.scad (EiNSTeiN variant) single plate for i31
I3-Platter.png
compact-extruder.scad (EiNSTeiN variant) dual extruder in build log images below1
I3-Compact-extruder-einstein.png
MGS Extruder T2.5 BeltsMGS branch of i3 single-frame parts bySound: i3-unterwelt at https://github.com/alexrj/Prusa3/tree/i3-unterwelt
mgs-body.stl1
Mgs-body.png
mgs-groovemount_ABS.stl1
I3-Mgs-groovemount-ABS.png
mgs-idler.stl1
I3-Mgs-idler.png
mgs-mount.stl1
I3-Mgs-mount.png
x-carriage.stl1
I3-mgs-X-carriage.png
Single-Frame i3Aluminium 6mm plate 370mm x 370mm
Prusa3ALU-FREZOVANY-v4.dxf1
I3-DXFPlate.png


Note:
The Prusa3 repository (below) includes frames for both aluminum and laser cut wood (sized for 6mm thick) for both the "single_plate" and "mini" variants. The wood frame files include two gussets, which stabilize the frame from flexing. Photos of each can be found at:

"single_plate": http://www.flickr.com/photos/sbgraber/sets/72157632513929965/with/8378333341/
"mini": http://www.flickr.com/photos/sbgraber/sets/72157632518684272/with/8379471692/

The Prusa3ALU-*.dxf and Prusa3WOOD-*.dxf feature y-carriages that use zipties to fasten three LM8UUs to the underside. Prusa3_SC10UU-*.dxf has mount holes for SC10UU linear bearing blocks. Use whichever carriage fits your need.



File Sources

Github:
https://github.com/josefprusa/Prusa3 - Josef Prusa - main development repository
https://github.com/alexrj/Prusa3/tree/i3-unterwelt - Sound MINI repository
https://github.com/EiNSTeiN-/Prusa3/ - EiNSTeiN - 608 bearings, compact dual extruder repository


Other Build Documentation

Single plate build pics: http://www.sub-design.co.uk/i3build/


Build Documentation:
http://78.47.92.212/i3_documentation_pics/

Build Videos:
http://www.youtube.com/watch?v=NixSNAUPciQ

JBFromOZ - notes preparing to build an aluminium frame prusa i3.

Prusa i1/i2 smooth rod lengths should be usable for an i3 single-plate reprap.

Instructions on the github say to RP each part in the single-plate folder. I believe this instruction applies to the box frame version only, some items need more than 1 copy.

Extruder Discussion

It is not yet 100% clear which extruder to use, there is a dual extruder and a compact extruder in the branch though neither looks complete. there is also a Greg's adapter in the /mini/extruder/greg-wade folder, it uses the nuts_and_bolts.scad which needs to be copied to the openscad library folder.

I am planning to use a MGS extruder with a Nema17 stepper, designs from Sound are shown from his i3-unterwelt branch

Build photos from EiNSTieN's build record, including some additional reference to his edits for 608 bearings, GT2 belts, dual extruders etc.

Build Instructions (With Pictures!)

DescriptionImage
build Y assembly using 4 x corners (RP), 1 x Y motor mount (RP), 1 x Y Idler mount (RP), 4 x M8 threaded rod short 2 x M8 threaded rod long, 2 x M3 x 8mm cap head bolts, (10mm perhaps with M3 washers) 36 x M8 nuts, 36 x M8 washers, 1 x stepper
I3-build-Ycarriageassy.jpg
Clean and de-burr aluminium 6mm plates., tap holes as required
I3-build-aliplates.jpg
Cable tie LM8UU's to Y carriage, and attach 1 x Y belt connection (RP), 2 x M3 x 10mm cap head bolts, 2 x M3 washers, 3 x LM8UU bearings 3 x cable ties, 1 x aluminium Y carriage.
I3-build-lm8uuYbeltholder.jpg
Attach Z mounts to Aluminium plate. 2 x upper Z mount (RP), 2 x lower Z mount (RP) 10 x M3 x 10mm (mounts to ali plate)
I3-build-Zmounts.jpg
Attach Z steppers and smooth rods. , 6 x M3 x 8mm Z motor to mounts (10mm with M3 washers). Install LM8UUs into the X Carriage (not onto rods as pictured)
I3-build-Zassembled.jpg
build X carriage and attach to ali plate
I3-build-XandZassemblies.jpg
attach Y assembly to ali plate
I3-build-assembly.jpg
attach and tension Y belt.
I3-build-ybeltattached.jpg
Attach and tension X belt.
I3-build-xcarriageconnection.jpg
Attach Heated Bed.
I3-build-bedmounted.jpg
build extruder assembly (dual extruder based on EiNSTeiN's branch as per above in these pictures)
I3-build-dualextruderassy.jpg
Attach Ramps (standoffs etc as shown)
I3-build-rampsstandoffs.jpg
Complete all wiring!
I3-build-ramps mounted.jpg
Attach Extruder
I3-build-assembled.jpg
Dual Printers!
I3-build-dualprinters.jpg
Dual Extrusion!
I3-build-2colourprint.jpg

Further specific details refer to wiring diagrams and other construction references on this wiki.