FoldaRap Build Manual

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FoldaRap Documentation
Index | FoldaRap Buyer's Guide | FoldaRap Build Manual | FoldaRap User Manual | FoldaRap improvements
FoldaRap 2.5

Contents

Previous Versions

The build manual for the previous versions are here :

Tools

General tips

  • Read the whole manual before starting to get an overview of the building steps (total: 12 hours of assembly).
  • The FoldaRap is made of a base frame and several sub-assemblies. Some can be done in parallel to save time, gather your friends and establish a new building time record !
  • Work on a cutting mat if you have one: it will protect your table plus they often show a millimetre grid that can be useful to check the bolts length (with experience you will recognize them by looking or holding one).
  • Place your mouse over a picture to know the element name.
  • Do not hesitate to have a look at the 3D model in Sketchup (before/during the build): it will show you the folded/unfolded state of the machine and you can play around with it.

Printed/Lasercut Parts

Insert a T-nut

Step 1/20 - Base Frame (30 min)

Foot-front-left.png x1 foot front left Foot-front-rightt.png x1 foot front right 20x20 200mm.jpg x2 200mm profile M4x8 round-head.jpg x4 M4x8 T-nut.jpg x4 T-nut

Foot-front-left.png x1 foot rear right Foot-front-rightt.png x1 foot rear left 20x20 200mm.jpg x2 200mm profile M4x8 round-head.jpg x4 M4x8 T-nut.jpg x4 T-nut

FR2-5-hinge-inner-left.png x1 hinge inner left FR2-5-hinge-inner-right.png x1 hinge inner right 20x20 300mm.jpg x4 300mm profile M4x8 round-head.jpg x10 M4x8 T-nut.jpg x10 T-nut

Step 2/20 - Y-axis (30 min)

FR2-5-y-idler.png x1 y-idler FR2-5-y-motor.png x1 y-motor M4x8 round-head.jpg x2 M4x8 T-nut.jpg x2 T-nut

Y-idler

FR2-5-y-idler.png x1 y-idler M3x25TCHC.jpg x1 M3x25 M3 washer.jpg x2 M3 washer 603zz.png x2 603zz bearing M3 nut.jpg x1 M3 nut

Y-motor

FR2-5-y-motor.png x1 y-motor Nema14.jpg x1 nema 14 M3x8.jpg x2 M3x8 Timing pulley2.png x1 pulley FRM-screw threads x3.png x2 grub screw

Y-idler & motor

Rod-idler

FR2-5-rod-idler-front-left.png x4 rod-idler M4x8 round-head.jpg x4 M4x8 T-nut.jpg x4 T-nut

Step 3/20 - Plug (45 min)

Cable 1

6,35mm-faston-ferule.jpg x1 4,8mm ferule (+ insulation) 6,35mm-faston-ferule.jpg x1 6,35mm ferule (+ insulation)

Cable 2

6,35mm-faston-ferule.jpg x1 4,8mm ferule (+ insulation) 6,35mm-faston-ferule.jpg x1 6,35mm ferule (+ insulation)

Cable 3

6,35mm-faston-ferule.jpg x1 4,8mm ferule (+ insulation)

Cable 4

6,35mm-faston-ferule.jpg x1 4,8mm ferule (+ insulation)

Cable 5

6,35mm-faston-ferule.jpg x1 6,35mm ferule (+ insulation)

Plug-plate

FR2-5-plug-plate.png x1 plug-plate C14 CEI male-plug.jpg x1 plug Switch.jpg x1 switch M3x8.jpg x2 M3x8 M3 nut.jpg x1 M3 nut

M4x8 round-head.jpg x4 M4x8 T-nut.jpg x4 T-nut

Step 4/20 - Underplate (20 min)

Power supply fixing

FR2-5-underplate.png x1 underplate FRM-power-supply-150w.png x1 power supply M3x8.jpg x2 M3x8 M3 nut.jpg x2 M3 nut

Underplate fixing

M4x8 round-head.jpg x4 M4x8 T-nut.jpg x4 T-nut

Power supply wiring

Step 5/20 - Z-axis (1 hour)

Z-motors (1/2)

FR2-5-z-motor-left.png x1 z-motor left FR2-5-z-motor-right.png x1 z-motor right 20x20 300mm.jpg x2 300mm profile M4x8 round-head.jpg x2 M4x8 T-nut.jpg x2 T-nut

Outer hinges

FR2-5-hinge-outer-left.png x1 hinge outer left FR2-5-hinge-outer-right.png x1 hinge outer right M4x8 round-head.jpg x2 M4x8 T-nut.jpg x2 T-nut

Z-motors (2/2)

Nema14.jpg x2 nema 14 M3x8.jpg x4 M3x8

Z-sliders

FR2-5-z-slider-left.png x1 Z-slider left FR2-5-z-slider-right.png x1 Z-slider right M3x30 countersunk-head.jpg x1 M3x30 countersunk

Z-axis

M3 nut.jpg x2 M3 nut M3x8.jpg x2 M3x8

M4x8 round-head.jpg x4 M4x8 T-nut.jpg T-nut.jpg x4 T-nut

Step 6/20 - X-axis (1 hour)

FR2-5-x-slider.png x1 x-slider 20x20 200mm.jpg x1 200mm profile FRM-screw threads x3.png x4 grub screw

Nema14.jpg x1 nema 14 Timing pulley2.png x1 pulley FRM-screw threads x3.png x2 grub screw

M3x30 countersunk-head.jpg x4 M3x30 countersunk 603zz.png x2 603zz bearing FRM-belt.png x1 250mm belt

FR2-5-x-belt-end.png x2 x-belt end M4x8 round-head.jpg x2 M4x8 T-nut.jpg x2 T-nut

Step 7/20 - Hotend (1 hour)

FRM-heater-block.png x1 heater block FRM-nozzle.png x1 nozzle FRM-barrel.png x1 barrel

FRM-cartridge-heater.png x1 cartridge heater FRM-screw threads x3.png x1 grub screw

FRM-thermistor.png x1 thermistor FRM-screw threads x3.png x1 grub screw

FRM-hotend-heatsink.png x1 heatsink FRM-pneumatic-fitting-MA1203M5.png x1 pneumatic fitting FRM-PTFE-tube.png x1 PTFE tube FRM-screw threads x3.png x1 grub screw

FR2-5-hotend-holder.png x1 hotend holder M3x8.jpg x4 M3x8

FRM-end-piece.png x2 cable terminal

Fan404010.png x1 fan FRM-ferule.png x2 ferule FRM-heatshrink-tubing.png x2 heatshrink tubing

FR2-5-fan-railings.png x1 fan grill M3x8.jpg x4 M3x8 M3 washer.jpg x4 M3 washer

M3x25TCHC.jpg x2 M3x25

Step 8/20 - XZ-axis (1 hour)

M4x8 round-head.jpg x2 M4x8 T-nut.jpg x2 T-nut

FR2-5-z-top-left.png x1 z-top left FR2-5-z-top-right.png x1 z-top right M4x8 round-head.jpg x2 M4x8 T-nut.jpg x2 T-nut

M4x8 round-head.jpg x4 M4x8 T-nut.jpg x4 T-nut

FR2-5-handle.png x1 handle M4x8 round-head.jpg x2 M4x8 T-nut.jpg x2 T-nut

Flexible-coupling-1.png x1 flexible coupling FRM-screw threads x3.png x2 grub screw

M5-nylon-nut.png x2 nylon nut 230-235mm threaded-rod.jpg x1 threaded rod

Flexible-coupling-1.png x1 flexible coupling FRM-screw threads x3.png x2 grub screw M5-nylon-nut.png x2 nylon nut 230-235mm threaded-rod.jpg x1 threaded rod

FRM-screw threads x3.png x4 grub screw

Step 9/20 - Bed (1 hour)

M3x30 countersunk-head.jpg x3 M3x30 countersunk M3 nut.jpg x3 M3 nut Bed springs RS751455.jpg x3 spring

FR2-5-y-carriage.png x1 y-carriage Linear-bearing-1.png x3 linear bearing

M3x8.jpg x2 M3x8

FRM-belt.png x1 250mm belt

FR2-5-y-belt-clamp.png x1 belt clamp M3 nut.jpg x2 M3 nut

FR2-5-bed-adjuster.png x3 bed adjuster M3 nut.jpg x2 M3 nut

Smooth-rod-300mm.jpg x2 smooth rod

FRM-end-piece.png x2 end piece

Mini-fit fiche-femelle.jpg x1 2,54mm female ferrule 2-pin.png x1 2-pin casing

Step 10/20 - Endstops (30 min)

X-endstop

Micro-switch with-lever.jpg x1 endstop FRM-heatshrink-tubing.png x2 heatshrink tubing FRM-ferule.png x2 ferule

Y-endstop

Micro-switch with-lever.jpg x1 endstop FRM-heatshrink-tubing.png x2 heatshrink tubing FRM-ferule.png x2 ferule FR2-5-y-endstop-holder.png x1 y-endstop holder

Z-endstop

Micro-switch with-lever.jpg x1 endstop FRM-heatshrink-tubing.png x2 heatshrink tubing FRM-ferule.png x2 ferule

Step 11/20 - Blower (15 min)

Fan404010.png x1 blower FRM-ferule.png x2 ferule FRM-heatshrink-tubing.png x2 heatshrink tubing FRM-end-piece.png x2 end piece

Step 12/20 - Extruder (45 min)

FR2-5-extruder.png x1 extruder M3x16.jpg x1 M3x16 603zz.png x2 603zz bearing

FRM-pneumatic-fitting-MA1203M5.png x1 pneumatic fitting M3x25TCHC.jpg x1 M3x25 M3x10 2.png x2 M3x10

Nema14.jpg x1 nema 17 FRM-insert.png x1 insert FRM-screw threads x3.png x1 grub screw

M3x35.jpg x2 M3x35 Bed springs RS751455.jpg x2 spring M3 washer.jpg x2 M3 washer M3 nut.jpg x1 M3 nut

Step 13/20 - Electronic board (15 min)

Potentiometers adjustment

Electronic board fixing

FR2-5-board-mount-minitronics.png x2 board mount M3x8.jpg x2 M3x8

M3x8.jpg x2 M3x8

Step 14/20 - Wiring (45 min)

Motors

Electronic board

Step 15/20 - Adjustments (30 min)

Step 16/20 - Driver (15 min)

Step 17/20 - Firmware (15 min)

Step 18/20 - Software (35 min)

User interface

Testing

X testing

If the motor rotation is reversed go the the "readjustments" paragraph...

Y testing

If the motor rotation is reversed go the the "readjustments" paragraph...

Z testing

If the motor rotation is reversed go the the "readjustments" paragraph...

Hotend testing and adjustment

Extruder testing

If the motor rotation is reversed go the the "readjustments" paragraph...

Bed testing

Readjustments

Step 19/20 - Bed calibration (20 min)

Step 20/20 - Finishing touches (30 min)

Spiral sheath

Once your are sure that every part of the 3D-printer is adjusted you can bring the finishing touches:

Hinges-blocks

Pads

Spool holder

1st printing

Modelling

Netfabb Basic

Check the quality of your .stl file on Netfabb Basic: you might "repair" or re-arrange your .stl file on Netfabb

If the automatic repair doesn't wotk: use the red cross button to identify the origin of the problem and re-open your file under the CAD software extension to correct the problem manually (don't forget to re-export the model as a .stl file)

Slic3r

Define the printing parameters of your model in Slic3r

Pronterface

Drive your 3D-printer with Pronterface

Your FoldaRap is now ready. Have a lot of fun with your projects !