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 don't plan to create a company out of it, I'd better hope to see it grow on itself in the wild, just by indicating how to source it. 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 crowdsourcing 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
(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).
"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)
Total end cost for 1 machine : 300-400€ but closer to 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.
- A draft BOM is on Kitbom
- My spreadsheet is roughly the same as the following lists but less accurate.
Hardware
1 handle - KJN 5 20x20mm beam 6mm slot 200mm - KJN or see Aluminium_profile_Suppliers 6 20x20mm beam 6mm slot 300mm - KJN 47 M4 T-nut for 6mm slot - KJN 49 M4x8 round head bolt - Fix'n Vis Round Head Bolt 2 M3x4 / Hotend-heatsink(2) Fix'n Vis Bolts 18 M3x8 bolt / Z-motors (6), Y-motor (3), X-end-idler (2), psu (4), male plug (2), x-endstop (1) 2 M3x10 bolt / Hotend-heatsink (2) 7 M3x12 bolt / X-idler (2), extruder-idler (2), Y-belt-clamp (2), y-endstop (1) 4 M3x16 bolt / X-motor (3), extruder-fan (1) 8 M3x20 bolt / X-carriage (4), hinges axis (2), Y-idler (1), extruder-idler (1) 3 M3x30 bolt / bed leveling (3) 1 M3x35 / extruder spring (1) 4 countersunk M3x12 bolt / bed assembly (4) - Fix'n Vis Countersunk Bolts 31 M3 nut / hinges (2), X-carriage (4), X-idler (3), Y-carriage (8), extruder-idler (3), plug (2), extruder-fan (1), bed-plate (4), psu (4) - Fix'n Vis Nuts 3 M3 nylock nut / bed leveling (3) 5 M5 nut / extruder-idler pneumatic fitting (1),z-rodz (4) 16 M3 washer / x-motor (3), x-idler (4), y-idler (2), y-carriage (6), extruder-idler (1) - Fix'n Vis washer 2 polymer coupling - See this thread (ebay / emakershop) 6 linear bearing, LM6UU or if you can Igus RJMP-01-06 - See Bearing 4 300mm smooth rod 6mm - (can be salvaged from usual scanners and printers) or see Smooth-rod 2 230-235mm threaded rod M6 - Fix'n Vis 4 603zz bearings / X-idler (1), Y-idler (2), extruder-idler (1) - See Bearing 1 600mm T2.5 belt 5-6mm wide - RepRapWorld or see Belts_and_Pulleys 1 700mm T2.5 belt 5-6mm wide 2 T2.5 pulleys - Paoparts or see Belts_and_Pulleys 1 PTFE Tubing for bowden extruder (2mm inner diam. and 3mm outer), 300mm long - 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 or Mendel-Parts (see also Drive-gear) 1 extruder spring - See Springs (I use the C.068.100.0200.A from Vanel) 3 bed springs - See Springs (e.g. : 3,3 id ; 4,1 od ; 25 mm long ; 0,4mm filament diam ; 15 coils) some springs from pencil can work too (I use the C.040.040.0250.A from Vanel) 1 140x140mm Huxley heatbed alu plate 4mm thick - Paoparts 1 roll of kapton - See Kapton#Suppliers 1 length of spiral wrapping band for tidying the wires - RS227874 7 faston ferule - Radiospare to crimp the cable for the plug and the switch
Electronic
4 nema14 stepper motors - [1] 1 extruder motor - nema14 or geared stepper like the PGL35-048 [2] 1 Azteeg_X1 board and 4 stepper drivers - [3] 1 usb to mini-usb cable - [4] 3 miniature microswitch endstop 20mm - [5] 1 12V 10-20A power supply - RS 7066316 (100*150*35mm) / will be replaced by this one soon (need to update the .dxf of the underplate) 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 2 100k thermistors - Mouser 1 peltier element 12708 (40x40mm is enough) - ebay 2-3m of 18, 22 and 26 AWG wire (power 90cm, heat 140cm, sensors 250cm) mostly for the heaters and the switch/plug - Read also WiresAndConnectors
Laser cut parts
See the github repo
1 electronic under-plate 4mm thick (you can add another one on the top of the bed as a protection when travelling) 1 reprap.org plate 160x20mm, 4mm thick (+2 T-nut and M4x8) - optional but make a nice reference to the wiki :)
I'm using a laser for these parts but they can be done easily by hand with a simple saw and drill.
Printed parts (total : 20-21)
See also the github repo
foot front left foot front right foot rear left foot rear right hinge-inner left hinge-inner right hinge-outer left hinge-outer right z-motor-bracket left z-motor-bracket right z-top left z-top right y-motor y-idler y-carriage y-belt clamp x-end-motor x-end-idler x-carriage extruder-idler board mount
Other
- Padded suitcase
How to replicate a FoldaRap !
If you can print your own parts it will take ~400gr and 22h at ~30% infill
Material
I'd recommend PLA over ABS.
It's maybe only required for the parts that act as sliders on the aluminium extrusions (x-motor, x-idler), but there is still some big parts (the feet).
Recommended settings
- Nozzle diameter of reference : 0,5 mm
- Layer height : 0,25mm
- You need to have a well calibrated machine (+/- 0.05mm on measured parts) : http://forums.reprap.org/read.php?282,159683
Infill : 30-35% hexagonal or rectilinear or any dense pattern you like.
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.
Fully assembled machines
Not yet.
Partial or complete kit
- I listed all the parts on Kitify, waiting for the review process.
- create an account on Goteo.org and wait some month before the FoldaRap_Batch2 :D
