Prusa i3 Build Manual

From RepRapWiki
Jump to: navigation, search


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

Contents

Boxed style Frame Style

I3-box frame.png

In the future this page might contain a tutorial. Until then, a tutorial for the boxed frame style Prusa i3 by Kliment:

Rods

note check here for detailed instructions for where these numbers are derived from https://github.com/josefprusa/Prusa3/blob/master/box_frame/doc/dimensions.md

X Axis;

  • 2x 470mm M8 smooth rod
  • 1x 20mm M8 smooth (for extruder idler, use 8x20 threaded rod or grub screw instead as substitute)

If you want to play with the X length, you will have to cut the top (longest) plate as long as the smooth rod and one of the 450mm is actually (X rod length - 2x plate thickness) long. The rods may be longer, but should not be shorter by more than 1cm

Y Axis:

  • 2x 370mm M8 smooth rods
  • 2x 400mm M10 threaded rod
  • 2x 400mm M8 threaded rods (M10 is actually correct)
  • 4x 205mm M8 threaded rods

Z Axis:

  • 2x 405mm M8 smooth rod
  • 2x ~370mm M5 threaded rod

You could play with the Z lengths to increase building height.
For this you will need longer wood cut for 4 of the 450x100mm plates; The plates are (Z rod length + 45mm) long

Frame

Default is 12mm thick wood. Get something that is strong and not likely to warp (change shape) due to temperature and humidity! The thickness is mostly needed to hold the screws used hold the frame together and to mount parts onto it. The entire frame structure must be stiff, holding its shape reagardless of what it's sitting on.

  • 6x 450x100x12mm wood
  • 1x 475x100x15mm wood

Any wood _over_ 12mm thickness will not work for the bottom plate with default config, the Y will then be lifted from the ground.
So if you are using thicker wood for the frame, be sure to change board_thickness in configuration.scad before printing parts

Single Sheet Frame Style

I3-ali-prusa.jpg

http://www.flickr.com/photos/prusajr/8107645350/in/photostream

To reduce confusion, documentation of the EiNSTeiN variant has been moved to here JBFromOZ i3 Build Documents.

Documentation here will only be relevant to the "standard" single plate design. (whatever that actually means)

Materials

Single plate Version Rods: - updated to numbers from https://github.com/josefprusa/Prusa3/blob/master/box_frame/doc/dimensions.md

X Axis;

  • 2x 370mm 8 mm smooth rod
  • 1x 20mm 8 mm smooth (for extruder idler, use 8x20 threaded rod or grub screw instead as substitute)

Y Axis;

  • 4x 205mm M8 threaded - Note 210mm for nyloc nuts. If they are cut to exactly the same length will make assembly easier.
  • 2x 350mm 8 mm smooth rod - Note take care to cut to exactly same length.
  • 2x 380mm M10 threaded - Note M10 is correct.

Z Axis;

  • 2x 320mm 8 mm smooth rod.
  • 2x 300mm M5 threaded (or 320mm if you want it to protrude above the frame).

Rod Lengths:
http://titanpad.com/bU77NESnMC

In summary:

M5 Threaded M8 Smooth M8 Threaded M10 Threaded
2 x 300mm 2 x 370mm 4 x 205mm 2 x 380
1 x 20mm
2 x 350mm
2 x 320mm
600mm 2100mm 820mm 760mm

Note: Last row shows totals for each size/finish

Parts to be Purchased

BOM

There are a number of variants of i3 single plate.

The original Prusa variant BOM is located at https://docs.google.com/spreadsheet/ccc?key=0Aga03tFhujeidDJzR0ZJNFZQYkhXTXlWd1BLRkN4Nmc&usp=sharing

The JBFromOZ BOM, RP list and build info on his EiNSTeiN variant is here

The current BOM used by BotBuilder.net for their workshops is located here: http://www.botbuilder.net/documentation - Updated Oct. 2013.

The Sourcing Your Own Parts section of the i3 buyer's guide is an attempt to make a comprehensive parts list, with links and info on ordering individual components.

Rapid Prototype Parts

DescriptionQtyImage
RP Partslocated in Prusa/single_plate folder
z-axis-top.scad
preview
1
I3-Z-axis-top.png
z-axis-bottom.scad
preview
1
I3-Z-axis-bottom.png
y-motor.scad
preview
1
I3-Y-motor.png
y-idler.scad
preview
1
I3-Y-idler.png
y-corners.scad (M10 x 1 M8 x 2 holes)
preview
4
I3-Y-corners.png
y-belt-holder.scad
preview
1
I3-Y-belt-holder.png
x-end-motor.scad
preview
1
I3-X-end-motor.png
x-end-idler.scad
preview
1
I3-X-end-idler.png
x-carriage.scad
preview
1
I3-x-carriage.png
magnetic-holder.scad (used for hall effect sensors / endstops)
preview
2
I3-Magnetic-holder.png
fan-mount.scad
preview
1
I3-Fan-mount.png
belt-guide.scad (suit 623 bearing)
preview
4
I3-Belt-guide.png
Extruder optionsnot complete documentation at this stage
gregs-wade.scad (in box_frame/extras folder)
preview

(is this the same as Greg's Hinged Extruder?)

1 (???)
I3-Gregs-wade.png
greg-adapter.scad (in mini/extruder/greg-wade folder)1 (???)
I3-Greg-adapter.png
dual-extruder.scad (deprecated - experimental)1 (???)
I3-Dual-extruder.png
compact-extruder.scad (experimental - likely to be replaced by nema17 extruder)1 (???)
I3-Compact-extruder.png
Single-Frame i3Aluminium 6mm plate 370mm x 370mm
Prusa3ALU-FREZOVANY-v4.dxf1
I3-DXFPlate.png


Note:
The Prusa3 repository (below) includes frames for both aluminum and laser cut wood (sized for 6mm thick) for both the "single_plate" and "mini" variants. The wood frame files include two gussets, which stabilize the frame from flexing. Photos of each can be found at:

"single_plate": http://www.flickr.com/photos/sbgraber/sets/72157632513929965/with/8378333341/
"mini": http://www.flickr.com/photos/sbgraber/sets/72157632518684272/with/8379471692/

The Prusa3ALU-*.dxf and Prusa3WOOD-*.dxf feature y-carriages that use zipties to fasten three LM8UUs to the underside. Prusa3_SC10UU-*.dxf has mount holes for SC10UU linear bearing blocks. Use whichever carriage fits your need.


File Sources

Github

STLs:

  • Einstein stls: singleplate -->>[[1]] (generated 19/2/2014)
  • Einstein stls: boxframe -->>[[2]] (generated 19/2/2014)
  • vanilla stls:[[3]]


NOTE: developers are encouraged to link or post their sources but also printable stl files, currently (19/2/2014) some of the scad files are throwing errors or missing variable names or simply don't generate anything, instructions for generating stl files from scad files are unclear in terms of which ones to use, the above stl zip files may or may not be accurate however it's better than the previous situation,there are more zipped stl files to be done - thejollygrimreaper

Other Build Documentation

Build instructions of singe plate as an interactive animation

Notes:

  • JBFromOZ - notes preparing to build an aluminium frame prusa i3. EiNSTeiN variant [4]
  • Prusa i1/i2 smooth rod lengths should be usable for an i3 single-plate reprap.
  • Instructions on the github say to RP each part in the single-plate folder. I believe this instruction applies to the box frame version only, some items need more than 1 copy.

Extruder Discussion

It is not yet 100% clear which extruder to use, there is a dual extruder and a compact extruder in the branch though neither looks complete. there is also a Greg's adapter in the /mini/extruder/greg-wade folder, it uses the nuts_and_bolts.scad which needs to be copied to the openscad library folder.

I am planning to use a MGS extruder with a Nema17 stepper, designs from Sound are shown from his i3-unterwelt branch

Build photos from EiNSTieN's build record, including some additional reference to his edits for 608 bearings, GT2 belts, dual extruders etc.