FoldaRap Buyers Guide
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This project was for myself, as I needed a RepRap that is 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. And after 500 machines and few other models for the industry, I'm back to that principle :)
"Ideas are like living things and breed happily in an open-source context" as I like to think ^^ (on the same spirit I like this comment from User:Adrianbowyer)
Contents
Bill Of Material (BOM)
2017-10-14 : With the FoldaRap 3.0 I will maintain the new inventory in a Libre-Office datasheet. You can find it the github repo (here). I will progressively archive the BOM of the previous version below.
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 : ~400-600€ when you include all taxes and shipping costs. Make group orders with friends if you can.
Hardware
6 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) [1] 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 150mm x 140mm(4mm thick) 1 roll of kapton - See Kapton Tape#Vendors 20 zip-ties
Electronic
5 nema14 stepper motors - [2] 3 miniature microswitch endstop 20mm - [3] 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 [4] 1 USB cable A to B [5] 1 12V power supply : 5A (cold bed) or 10A or [6] (for heated bed)
or
1 Azteeg_X1 board - [7] + 4 drivers 1 usb to mini-usb cable - [8] 1 12V power supply : 10A
Laser cut parts
See the github repo, you can have them from Ponoko or OpenEdge too.
The bed can also be made of acrylic in case of a non-heated bed.
Other
- small drill bit (around the size of the nozzle) for the maintenance
- RS-1231938 is a good multimeter, it even include a thermocouple (e.g. : to externally check the temperature of the hotend)
How to replicate a FoldaRap !
If you can print your own parts it will take ~400gr and 22h at ~30% infill.
Material
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.
Recommended settings
- 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.
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The part that slide under it's own weight (16gr) have been slided back and forth a few time.