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).
Hardware or complete kit
Bill Of Material (BOM)
2015-07-20 : the BOM should be updated to reflect the latest changes, but there is only minor differences in hardware/vitamins between the 2.1 and the 2.5 version :)
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, or now for almost the same price I can make a kit for you.
5 20x20mm beam 6mm slot 200mm - Motedis or see Aluminium profile 6 20x20mm beam 6mm slot 300mm 54 M4 T-nut for 6mm slot - Motedis
54 m4x8 round head bolt - Fix'n Vis Round Head Bolt 4 m5 nylon nut / Z-rod (4)  3 m3 nylock nut / bed leveling (3) nylock nut 15 m3 nut / hinges (2), bed (3), Y-belt-clamp (2), extruder (2), plug (2), psu (4) - Fix'n Vis Nuts 8 m3x6 grubscrew / x-slider (4), pulley (4) 14 m3x8 bolt / Z-motors (4), Y-motor (2), psu (2), male plug (2), board-mount (2), hotend (2) - Fix'n Vis Bolts 8 m3x10 bolt / hotend (4), y-belt-clamp (2), extruder (2) 1 m3x16 bolt / extruder (1) 4 m3x20 bolt / hinges (2), Y-idler (1), extruder (1) 5 m3x25 bolt / hotend-holder (2), fan-holder (1), (extruder 1), z-endstop (1) 8 m3x30 countersunk bolt / x-slider (4), bed (3), z-endstop (1) 2 m3x35 / extruder (2) 2 230mm threaded rod m5 - Fix'n Vis
5 springs / extruder (2), bed (3) - RS751483 or see Springs 1m spiral wrapping band for tidying the wires - RS227874 7 6,35mm ferule - Radiospare to crimp the cable for the plug and the switch
2 5mm to 5mm flexible coupling 3 linear bearing, LM6UU or if you can Igus RJMP-01-06 - See Bearing 2 300mm smooth rod 6mm - (can be salvaged from usual scanners and printers) or see Smooth rod 5 603zz bearings / X-slider (2), Y-idler (2), extruder-idler (1) - See Bearing 1 250mm T2.5 belt 5mm wide - RepRapWorld or see Belts_and_Pulleys 1 600mm T2.5 belt 5-6mm wide 2 T2.5 pulleys - Belts_and_Pulleys 330mm PTFE Tubing for bowden extruder (2mm inner diam. and 3mm outer) - 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 aluminium bed plate (4mm thick) 1 roll of kapton - See Kapton Tape#Vendors 20 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 1m of 18AWG wire (200mm red, 200m black, 150mm green) for the switch/plug/psu - Read also WiresAndConnectors 10m of 26AWG (3.6m red, 3.2m green, 2.0m blue) for the sensors and fans 1 kapton film heater - Open Edge
1 Minitronic board  1 USB cable A to B  1 12V power supply : 5A (cold bed) or 10A or  (for heated bed)
Laser cut parts
The bed can also be made of acrylic in case of a non-heated bed.
Printed parts (total : xx)
See also the github repo
- 0.3mm drill bit  (or 0.5mm, depending of the nozzle) for the maintenance.
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 : 0,24mm
- Infill : 30% hexagonal
- 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.