Prusa i3

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Prusa i3 Documentation
Index | | Prusa i3 Buyer's Guide | Prusa i3 Build Manual | Prusa i3 User Manual | Prusa i3 improvements


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Prusa i3

Release status: working

Prusai3-metalframe.jpg
Description Prusa i3 is a redesign by Prusajr.
License GPL
Author Prusajr (design),
Based-on prusa i3
Categories Prusa i3, Prusa i3 Development, Prusa Development, Prusa Mendel Development, Prusa Mendel, Mendel Variations, Cartesian-XZ-head, RepRap
CAD Models none
External Link [1]


Contents

Introduction

The Prusa i3 (iteration 3) is the newest and most current 3D Printer design by RepRap Core Developer Prusajr. The i3 incorporates lessons learned from the previous two Prusa designs, as well as other popular modern RepRap designs. See also Prusa Mendel (iteration 2). Or Graber i3 all parts in MDF (cheaper).

Specifications

' Single Sheet Frame Box Frame
Plastic Parts (exc. Extruder) 26 29
Non Printed Parts approx. 337 293
Cost $300-1000? $300-$800?
Controller Electronics Almost all RepRap Almost all RepRap
Printing Size 200 x 200 x 200 200 x 200 x 270
Motors 5 x NEMA 17 Stepper 5 x NEMA 17 Stepper
Frame Material 6mm Aluminium, Wood 12mm Wood
Frame Manufacture Laser Cutter, CNC, Water Jet Basic Woodwork Tools
Pro Easy assembly Rigid XZ to Y Connection
Con Specialised Tools Looks less professional?

Main improvements

The following is a list of the main improvements made upon the Prusa Mendel Iteration 2

  • Enhanced frame rigidity (prevents x-axis backlash)
  • Easy assembly
  • Parametric files for multiple sizes/bearings or bushings

Development

The development of the Prusa Mendel is hosted on github: https://github.com/josefprusa/Prusa3.

History

Printed Parts

The STL files to make the printer can be found at Clone_wars:_Prusa_iteración_3. and here zipped up: File:Clonewars.zip Please note that the zipped files are not compatible with holes for the Z axis brackets in the Prusa3ALU-*.dxf drawings, at least the ones in the old/ folder in github. Also, the models for Y-axis brackets are for M8 rods. Compiling your own and investigating the Prusa github packages is highly recommended!


To compile it yourself use the files from Github [[2]] (box style files) [[3]] (Single sheet style) Copy configuration.scad.dist to configuration.scad and fill custom settings section there


RP every .scad in this directory (except complete-printer) once. Aim for 0.3mm layers and 2.2 extrusion width (width over thickness), for 0.66mm stroke width. Printer is tested at this setting.

Using doc/complete-printer.scad as a visual clue and doc/manual.txt as a guide, build the printer.

Frame type

Most major Prusa i3 Frame Styles fall into two categories: the Single Sheet Frame, and the Box Style Frame. The Single Sheet Frame is designed to be manufactured through the use of a Laser cutter, WaterJet, or CNC Mill / Router Table. There are two current development tracks within the Single Sheet Frame, an Aluminium frame style, and a gusseted Wood frame style. Both are designed to support 6mm or thicker framing material. Both the EiNSTeiN variant and the i3 Rework designs use single sheet aluminum frames, as do most kits. The Box Style Frame, on the other hand, is designed to be easily manufactured at home with basic woodworking tools. The Y-axis for both frame styles is similar to that of the older Prusa Mendel Iteration 2.



Single Sheet Frame

This is a frame created from a single sheet of metal, typically Aluminum, but can also be made from various Materials with a thickness greater than 6mm / 0.25 inch

Prusa i3 with a single metal sheet style frame.
Prusa i3 with a single metal sheet style frame.


pro:

- Looks professional (subjective)

con:

- Requires specialised tools (e.g. Water flow jet cutter)

- Less rigid connection between XZ-frame and Y-frame part, however this can be somewhat rectified by the TwelvePro variant, which provides additional frame support.



Wood Sheet frame

Wood Style Sheet Frame
Wood Style Sheet Frame
Wood Style Sheet Frame Made Out Of Melamime
Wood Style Sheet Frame Made Out Of Melamime

This is a version of the sheet frame that is designed to be laser cut out of wood or plastic (eg. acrylic) if you don't have access to a waterjet cutter. The only difference is that this version has support gussets on the back side of the vertical frame (the side that doesn't have the z threaded rods).

Construction is the same.

Laser cutting files can be found at github.com/sgraber/Prusa3_LC.

pro:

- Looks professional (subjective)

con:

- Requires specialized tools (e.g.laser cutter)

- Less rigid connection between XZ-frame and Y-frame part (Connects in the same way as the alu sheet frame)



Box Style Frame

This frame is created from 8 small sheets of wood.

Prusa i3 with a box style frame.
Prusa i3 with a box style frame.


pro:

- Can be created with standard DIY tools

- More rigid connection between XZ-frame and Y-frame part

con:

- Looks less professional (subjective)



Alternate Box frame

A Alternate box style frame.
A Alternate box style frame.

This is a version of the boxed frame that uses only 5 parts instead of 8. It requires a little more work when cutting out the parts but less work to assemble.

Blueprints for the box can be found Here[4]

Electronics

Stepper Motors

The Prusa i3 uses, including the extruder, 5 NEMA17 stepper motors. Two of these motors, the Z axis motors, are connected to the same stepper driver of the electronics. If using Wade's Extruder, its stepper motor needs a minimum holding torque of 40Ncm (0.4Nm). More information can be found on the Stepper Motor page.

Controller Electronics

About any RepRap controller works for the Prusa i3. Required features: 4 stepper drivers, 1 thermistor input and 1 heater output for the extruder and optionally another thermistor/heater pair for the heated bed. Choosing the best one for your printer is mostly a matter of taste. For comparisons, see List of electronics, Comparison of Electronics and Alternative Electronics.

Extruder

Extruder

On November 12th, 2012 Josef Prusa (@josefprusa) tweeted a picture of his metal frame i3 with a custom dual extruder mounted.

Prusa i3 with an unnamed dual extruder mounted.
Prusa i3 with an unnamed dual extruder mounted.

//Need name, info, and link to this extruder and how to build it. Can anyone help? -idolcrasher

Previous posts on Prusa's twitter feed reveal that Sound (Slic3r's Developer) inspired Prusa to attach a dual extruder.

Heated Bed

The Prusa i3 includes a Heated Bed which allows for the use of materials such as ABS and nylon which can experience significant warping if printing on a cold platform.

  • MK3 heating bed, aluminum plate thickness of 3 mm, uniform heating, fast, back has good heat preservation, high temperature can be heated to 120 degrees

I3-12.jpg

Filament Holder

For Sheet Style,

For Box Style,

Videos


TODO add more solutions