FoldaRap Build Manual

From RepRapWiki
Jump to: navigation, search
FoldaRap Documentation
Main page | FoldaRap Buyer's Guide | FoldaRap Build Manual | FoldaRap User Manual | FoldaRap improvements
FoldaRap 2.6

Contents

Previous versions

The build manual for the previous versions are here :

Tools

Included tools

Tools to provide

Bonus 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 parts

Lasercut parts

Screws & bolts box

The screws and bolts are arranged in their box according to the assembly steps to simplify their identification.

Use environment

  • Dry environment
  • Room temperature (between 5°C and 35°C)
  • Protected from dust
  • On flat surfaces
  • Protected from inflammable substances
  • Apart from other electronic devices

A use out of these conditions can damage your 3D-printer...

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)

Y-idler

FR2-5-y-idler.png x1 y-idler M4x8 round-head.jpg x1 M4x8 T-nut.jpg x1 T-nut M3x25TCHC.jpg x1 M3x20 M3 washer.jpg x1 M3 washer 603zz.png x2 603zz bearing M3 nut.jpg x1 M3 nut

Y-motor

FR2-5-y-motor.png x1 y-motor M4x8 round-head.jpg x1 M4x8 T-nut.jpg x1 T-nut 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 + switch (45 min)

Cable 1

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

Cable 2

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

Cable 3

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

Cable 4

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

Cable 5

6,35mm-faston-ferule.jpg x1 6,35mm ferrule (+ 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 x2 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 M3x20.jpg x2 M3x20

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

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

M22-x-slider.png x1 x-carriage 20x20 200mm.jpg x1 200mm profile FRM-screw threads x3.png x6 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)

Heater block

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

Heatsink

FRM-hotend-heatsink.png x1 heatsink FRM-pneumatic-fitting-MA1203M5.png x1 pneumatic fitting FRM-PTFE-tube.png x1 PTFE tube (2-4 mm) FRM-screw threads x3.png x1 grub screw

Thermistor

FRM-thermistor.png x1 thermistor Mini-fit fiche-femelle.jpg x2 female ferrule 2.54 mm 2-pin.png x1 2-pin casing

Cartridge heater

FRM-cartridge-heater.png x1 cartridge heater FRM-screw threads x3.png x1 grub screw FRM-end-piece.png x2 cable terminal (1.5 mm)

Fan

Fan404010.png x1 fan FRM-ferule.png x2 ferrule (1mm) FRM-heatshrink-tubing.png x2 heatshrink sleeve

FR2-5-fan-railings.png x1 fan-grill M3x8.jpg x4 M3x16

Hotend holder

M22-hotend-holder.png x1 hotend holder M3x8.jpg x4 M3x8

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 20x20 200mm.jpg x1 200mm profile 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

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

Flexible-coupling-1.png x1 flexible coupling M5-nylon-nut.png x2 nylon nut 230-235mm threaded-rod.jpg x1 threaded rod

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 Zipties.jpg x4 zip-tie

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 x3 M3 nut

Smooth-rod-300mm.jpg x2 smooth rod

Zipties.jpg x5 zip-tie

FRM-end-piece.png x2 cable terminal

Mini-fit fiche-femelle.jpg x2 female ferrule (2.54mm) 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 sleeve FRM-ferule.png x2 ferrule

Y-endstop

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

Step 11/20 - Blower (15 min)

Fan404010.png x1 blower FRM-ferule.png x2 ferrule FRM-heatshrink-tubing.png x2 heatshrink sleeve FRM-end-piece.png x2 cable terminal (1mm)

Step 12/20 - Extruder (45 min)

M3-0-extruder-corps.png x1 extruder 1 M3-0-extruder-levier.png x1 extrudeur 2 M3-0-extruder-capot1.png x1 extrudeur 3 M3x16.jpg x1 M3x10 603zz.png x1 603zz bearing

FRM-pneumatic-fitting-MA1203M5.png x1 pneumatic fitting

M3x25TCHC.jpg x1 M3x25

Bed springs RS751455.jpg x1 spring

M3x25TCHC.jpg x3 M3x25

Nema14.jpg x1 nema 17 FRM-insert.png x1 insert (+ grub screw)

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)

E-motor

X-motor

Y-motor

Z-motors

Electronic board

Step 15/20 - Printing surface (30 min)

Kapton (option 1)

PrintBite (option 2)

Step 16/20 - Driver (15 min)

Step 17/20 - Firmware (15 min)

Step 18/20 - Software (35 min)

User interface

Testing

Preparation

Switching on

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

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

Spool holder

FR2-5-spool-holder.png x1 spool-holder M4x8 round-head.jpg x1 M4x8 T-nut.jpg x1 T-nut

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

Upkeep

The FoldaRap doesn't need much upkeep. Anyway it's important to look carefully at the following points:

1. Make sure that your printing surface is always clean : if you put finger mark or grease / oil on your bed use a dry and clean duster to clean the bed while it is cold; 2. Put some oil on the X and Z aluminium extrusion profiles (once a month) ; 3. If you notice that the extrusion width decreases compared with your first prints then your nozzle is probably clogged... heat the nozzle around 260°C (not more) and push by hand the filament through the nozzle: the blockage should go out of the nozzle and it will become easier to extrude the melted plastic. If not, you will have to disassemble the nozzle from the rest of the extrusion head, put it on an electric hotplate and heat it around 300°C for 1 hour (the blockage should sublimate).

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