RepRap Samuel
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Release status: working
| Description | Silpstream's Augmented Mendel a.k.a Samuel
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Contents
Introduction
RepRap Samuel is designed to reuse the vitamins and some parts from the Prusa Mendel i2 or the Mendel. As such, an owner of either of the RepRaps should be able to print the new parts on their existing 3D printer to rebuild it into Samuel. It's design objectives are:
- Reuse vitamins and parts from RepRap Mendel
- Increase build volume in the Z-axis
- Improve X-motion stability
- Upgrade X-axis to newer vertical designs
CREDITS
The following components were used in this project:
- Unbreakable Bar Clamp by mikepcw - [1]
- Prusa Leveling Vertex by Ahasuerus - [2]
- Bed levelling thumb wheel by Wired1 - [3]
- 40mm Supportless, Directed Cooling Fan Duct for MendelMax & Prusa by AeroMonkeyDork - [4]
- The frame stabiliser was also from Thingiverse, but the thing seems to have been removed.
Iso view 1
Iso view 2
Front view
Left view
Right view
Back view
Direct-drive extruder close-up
Y-Motor mount close-up 1
Y-Motor mount close-up 2
Z-Motor mount close-up
Z-Axis top support close-up
Specification
- Size: 420x420x440mm
- Build Volume: 196m x 196 mm x 200mm
- 5 x NEMA 17 motors
- Electronics: Should work with most RepRap electronics
- Structural materials: M8 rods, ABS/PLA
Parts
M8 Rods
The quantity and lengths of the rods are the same as that of the Prusa Mendel i2.
| Quantity | Part | Comment | 6 | 370mm M8 threaded rod | 2 used at rear of frame. 2 used to connect front and rear of frame. 2 used to create vertical frame. Longer is okay. | 4 | 294mm M8 threaded rod | 2 used at front of frame, and 2 more diagonally to support the vertical frame. Longer is okay. | 3 | 440mm M8 threaded rod | 2 are used to secure the z-motor mount, while one goes across as top support. Longer is okay. | 2 | 210mm M8 threaded rod | Used for the z-axis. Longer is better to give more build height. Can also be replaced with 8mm lead screws or M5/M6 but you'll need to make a nut adaptor. | 2 | 350mm 8mm smooth rod | Used for the z-axis, cannot be shorter than 330mm. Longer is okay. | 2 | 405mm 8mm smooth rod | Used for the y-axis, must not be shorter than 405mm. Longer is okay. | 2 | 420mm 8mm smooth rod | Used for the x-axis, cannot be shorter than 410mm. Longer is okay. |
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Bearings
| Quantity | Part | Comment | 4 | 608zz | 2 are optional as you only need one in front and 1 in rear. Look at pictures for better understanding. | 5 | 623z | Only need 4 if you choose not to use the direct drive extruder in this project. 2 used of x-idler. 2 used for y-motor mount. | 1 | 625zz | You need this only if you want to support the shaft on the y-motor. | 10 | LM8UU | 3 for print bed, 3 for x-carriage, and 4 for x-ends. | 2 | F8-19M | These are optional trust bearings that are used on the z-axis. The bearing dimensions are 8mmx19mmx7mm. |
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Printed
You can find all files on reprap_samuel@GitHub.
| Picture | Part | Comment | 
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sam_20deg-sup-L.stl sam_20deg-sup-R.stl |
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sam_20deg-vertex-L.stl sam_20deg-vertex-R.stl |
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third_party/prusa-leveling-vertex-M8-M4.stl | 
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sam_vertex-L.stl sam_vertex-R.stl |
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sam_crossbar-sup-L.stl sam_crossbar-sup-R.stl |
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sam_z-axis-top-sup-L.stl sam_z-axis-top-sup-R.stl |
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third_party/Stabilizer_M_2sides.stl | 
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sam_z-motor-mount-top-L.stl sam_z-motor-mount-top-R.stl |
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sam_z-motor-mount-btm-L.stl sam_z-motor-mount-btm-R.stl |
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sam_leveling-foot.stl | 
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sam_direct-drive-parts.stl | 
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sam_direct-drive-parts.stl | 
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sam_extruder-jhead-base.stl | 
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sam_extruder-jhead-clamp.stl | 
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sam_x-carriage.stl | 
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sam_x-belt-clip.stl | 
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sam_fan-arm.stl | 
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sam_fan-mount.stl | 
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third_party/FanDuct-Supportless_v2.stl | 
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sam_x-end-clamps.stl | 
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sam_x-end-idler.stl | 
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sam_x-end-motor.stl | 
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sam_x-end-pulley-spacer.stl | 
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sam_x-end-pulley.stl | 
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sam_x-end-rod-spacer.stl | 
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sam_x-end-tensioner.stl | 
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third_party/bar-clamp_pinchclamp3.stl | 
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sam_y-bed-support-L.stl sam_y-bed-support-R.stl |
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third_party/Thumb_wheel_slim.stl | 
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sam_y-lm8uu-no-spring.stl | 
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sam_y-lm8uu-nut-retainer.stl | 
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sam_y-lm8uu-spring.stl | 
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sam_t25-belt-clamp-parts.stl | 
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sam_t25-belt-clamp-parts.stl | 
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sam_t25-belt-clamp-parts.stl | 
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sam_t25-belt-clamp-parts.stl | 
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sam_t25-belt-clamp-parts.stl | 
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sam_y-motor-L.stl sam_y-motor-R.stl sam_y-motor-pulley-spacer-sml.stl |
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Build
Detailed pictures to show how the parts go together.
Front portion of the base. 2 x 608zz bearings were used. 2 x 294mm M8 threaded rod is used for the front.
Optionally use 2 x 210mm M8 threaded rod instead so that the 294mm ones can be used for z lift. (Picture shows 294mm being used)
Rear portion of the base. 2 x 608zz bearings were used.
2 x 370mm M8 threaded rod is used for the rear.
Front and rear is joined using 2 x 370mm M8 threaded rod.
Cross-brace should be added at this stage.
Add the Z-motor mounts on each side using 2 x 440mm M8 threaded rod.
Ensure that motor mount holes line up with rear vertex holes.
2 x 370mm M8 threaded rod is used for the vertical support. 1 x 440mm M8 threaded rod is used for the horizontal support.
2 x 294mm M8 threaded rod is used for the diagonal support to join the rear vertex to the z-motor mount.
XZ are added on. 2 x 420mm smooth rod is used horizontally (x-motion). 2 x 623zz bearings were used for the x-end idler.
2 x 3500mm smooth rod is used vertically (z-motion). Add LM8UUs as required.
A J-head hotend is secured using the clamp and 2 x M3 screws.
If J-head has a bolt on top, it will have to be removed and reattached after mounting on the base.
2 x M3 nuts fit into the side of the base to secure the clamp.
Completed Y-axis motor mount.
4 x M3 screws are used to secure the stepper to both parts of the mount. (Optionally 1 x 625zz bearing can be used to support the stepper shaft.
The stepper motor should fit into the mount to provide maximum support.
Adjust the spacers and 2 x 623zz bearings so that it lines up with the teeth of the gear.
