FoldaRap Buyers Guide
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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 Open 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).
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.
5 20x20mm beam 6mm slot 200mm - Motedis or see Aluminium_profile_Suppliers 6 20x20mm beam 6mm slot 300mm 50 M4 T-nut for 6mm slot - Motedis
50 m4x8 round head bolt - Fix'n Vis Round Head Bolt 2 m3x4 / Hotend-heatsink(2) Fix'n Vis Bolts 15 m3x8 bolt / Z-motors (4), Y-motor (3), X-end-idler (2), psu (2), male plug (2), board-mount (2) 2 m3x10 bolt / hotend (2) 6 m3x12 bolt / X-idler (1), extruder (3), Y-belt-clamp (2) 4 m3x16 bolt / X-motor (3), extruder-fan (1) 7 m3x20 bolt / X-carriage (3), hinges (2), Y-idler (1), extruder (1) 3 m3x30 countersunk bolt / bed (3) 2 m3x35 / extruder (2) 19 m3 nut / hinges (2), X-carriage (3), X-idler (2), extruder-fan (1), bed (3), Y-belt-clamp (2), extruder (2), plug (2), psu (2) - Fix'n Vis Nuts 3 m3 nylock nut / bed leveling (3) nylock nut 5 m5 nut / extruder pneumatic fitting (1), Z-rod (4) (for the Z nylon nuts can be slightly better) 11 m3 washer / X-motor (3), X-idler (2), extruder (2), Y-idler (2), Y-belt-clamp (2) - Fix'n Vis washer 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 faston ferule - Radiospare to crimp the cable for the plug and the switch
2 polymer coupling - See this thread (ebay / emakershop) 6 linear bearing, LM6UU or if you can Igus RJMP-01-06 - See Bearing 4 300mm smooth rod 6mm - (can be salvaged from usual scanners and printers) or see Smooth rod 4 603zz bearings / X-idler (1), Y-idler (2), extruder-idler (1) - See Bearing 1 600mm T2.5 belt 5-6mm wide - RepRapWorld or see Belts_and_Pulleys 1 700mm T2.5 belt 5-6mm wide 2 T2.5 pulleys - Paoparts or see Belts_and_Pulleys 1 PTFE Tubing for bowden extruder (2mm inner diam. and 3mm outer), 300mm long - 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 bed plate 4mm thick 1 roll of kapton - See Kapton Tape#Vendors 20-30 zip-ties
5 nema14 stepper motors -  3 miniature microswitch endstop 20mm -  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 0.6 m of 18AWG wire (200mm red, 200m black, 150mm green) for the switch/plug/psu - Read also WiresAndConnectors 10 m of 26AWG (3.6m red, 3.2m green, 2.0m blue) for the sensors and fans
1 Minitronic board  1 USB cable A to B  1 12V power supply : 5A or 10A or  (for heated bed)
1 Melzi board ,  1 usb to mini-usb cable -  1 12V power supply : 5A or 10A or  (for heated bed)
1 Rumba + 6 stepper drivers 1 usb to mini-usb cable -  1 12V power supply : 20A (RS 7066316 100*150*35mm)
Laser cut parts
1 electronic under-plate 3-4mm thick 1 bed-plate 4-6mm thick (acrylic or aluminium) 1 Y-carriage 1 reprap.org plate 160x20mm, 2-4mm thick (+2 T-nut and M4x8) - optional but make a nice reference to the wiki :)
These parts can also be made by hand with simple tools.
Printed parts (total : 21)
See also the github repo
foot front left foot front right foot rear left foot rear right hinge-inner left hinge-inner right hinge-outer left hinge-outer right z-motor-bracket left z-motor-bracket right z-top left z-top right y-motor y-idler y-belt clamp x-end-motor x-end-idler x-carriage extruder-idler board mount (x2)
For the aluminium heated bed add :
1 aluminium bed plate (4mm thick) 1 100k thermistors - Mouser 60cm of 26 AWG wire (blue) 2 ferule 0,5mm² 1 peltier element 12708 (40x40mm is enough) - ebay
- EU : http://www.abylon.fr/145-valise-olycase-500.html
- FR : http://www.vexi.fr/valises-plastique/etanches
- US : http://www.amazon.com/Nanuk-Case-Cubed-Foam-Black/dp/B003JH7ZU4/
- 0.3mm drill bit  (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.
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.
- 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
I recorded this little video where I'm playing with some parts freshly printed, to show what to expect about the tight tolerances.The part that slide under it's own weight (16gr) have been slided back and forth a few time.
Fully assembled machines
Partial or complete kit
- mendbot-shop (quality of printed part is not known)
- Spares 3d on eMakerShop (1.0)
- 3d Andy on eMakerShop (1.1 + geared extruder)
- A draft BOM is on Kitbom
- My spreadsheet is roughly the same as the following lists but a little outdated.
6 300 mm 6 400 mm
50 M4x8 8 M4x12 (hinges) 2 M4x16 (hinges)