Prusa i3 Build Manual
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Boxed style Frame Style
In the future this page might contain a tutorial. Until then, a tutorial for the boxed frame style Prusa i3 by Kliment:
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
- 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
- 2x 370mm M8 smooth rods
- 2x 400mm M10 threaded rod
2x 400mm M8 threaded rods(M10 is actually correct)
- 4x 205mm M8 threaded rods
- 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
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
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)
Single plate Version Rods: - updated to numbers from https://github.com/josefprusa/Prusa3/blob/master/box_frame/doc/dimensions.md
- 2x 370mm 8 mm smooth rod
- 1x 20mm 8 mm smooth (for extruder idler, use 8x20 threaded rod or grub screw instead as substitute)
- 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.
- 2x 320mm 8 mm smooth rod.
- 2x 300mm M5 threaded (or 320mm if you want it to protrude above the frame).
|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|
Note: Last row shows totals for each size/finish
Parts to be Purchased
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 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
|RP Parts||located in Prusa/single_plate folder|
|y-corners.scad (M10 x 1 M8 x 2 holes)|
|magnetic-holder.scad (used for hall effect sensors / endstops)|
|belt-guide.scad (suit 623 bearing)|
|Extruder options||not complete documentation at this stage|
|gregs-wade.scad (in box_frame/extras folder)
(is this the same as Greg's Hinged Extruder?)
|greg-adapter.scad (in mini/extruder/greg-wade folder)||1 (???)|
|dual-extruder.scad (deprecated - experimental)||1 (???)|
|compact-extruder.scad (experimental - likely to be replaced by nema17 extruder)||1 (???)|
|Single-Frame i3||Aluminium 6mm plate 370mm x 370mm|
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:
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.
- https://github.com/josefprusa/Prusa3 - Josef Prusa - main development repository - scad file sources only available
- https://github.com/alexrj/Prusa3/tree/i3-unterwelt - Sound MINI repository, MGS extruder repository (files for parts shown above) - scad file sources and stl files available
- https://github.com/EiNSTeiN-/Prusa3/ - EiNSTeiN - 608 bearings, compact dual extruder repository, note that Y ends for M10 not M8 rods - scad file sources only available
- https://github.com/josefprusa/Prusa3-vanilla/tree/master/distribution - vanilla - used by josef prusa in his workshops - scad file sources and stl files available
- https://github.com/Joaz/machine_parts/tree/master/mgs_prusa - Joaz - MGS extruder repository (parts not shown above)
- https://skydrive.live.com/?cid=61d9a16368c58a74&id=61D9A16368C58A74!107&ithint=file,.rar&authkey=!AOcaZeSUEgaTCBA - 3D Printer Czar - STLs with improved Y belt holder
- Einstein stls: singleplate -->>[] (generated 19/2/2014)
- Einstein stls: boxframe -->>[] (generated 19/2/2014)
- vanilla stls:[]
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
- Acrylic frame build document by 3D Printer Czar: https://skydrive.live.com/redir?resid=61D9A16368C58A74!113&authkey=!AI2iTJjJC1ZxdG0&ithint=file%2c.pdf
- Single plate build pics: http://www.sub-design.co.uk/i3build/
- Prusa i3 Frame Kit Build Manual by ReprapUniverse.com: http://dl.dropboxusercontent.com/s/femvh8j5njf4sag/prusa_i3_frame_kit_build_manual.pdf
- Build Documentation: http://18.104.22.168/i3_documentation_pics/
- BotBuilder.net Workshop Build Documentation - (50 page PDF)
- Build Videos
Build instructions of singe plate as an interactive animation
- As a Linux binary
- As an online tool that works in Windows and OSX.
- New Design complete laser cut kit assembly: http://twelvepro.com/news/?page_id=31
- JBFromOZ - notes preparing to build an aluminium frame prusa i3. EiNSTeiN variant 
- 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.
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.