HackerBot structure
Contents
- 1 Base structure
- 1.1 Step 1: base with supports
- 1.2 Step 2: base with internal brackets
- 1.3 Step 3: Vertical structure
- 1.4 Step 4: tighten base with column
- 1.5 Step 5: insert supports in the column
- 1.6 Step 6: lower Z profile / Z motor mount
- 1.7 Step 7: front middle profile
- 1.8 Step 8: right middle profile
- 1.9 Step 9: left middle profile
- 1.10 Step 10: Upper Z backside profile
- 1.11 Step 11: Backside Top profile
- 1.12 Step 12: Top Right profile
- 1.13 Step 13: Top Left profile
- 1.14 Step 14: Top Front profile
Base structure
Hackerbot 2.0 uses MISUMI profile, but you can also use Bosch-Rexroth
TIP: Bosch-Rexroth extrusions profile are usually sold in bars of length 5600 mm. You need one bar and half for one HackerBot, about 8.5 meters.
To optimize bars cutting, our advice is to divide the whole bar in two parts, with length 2700 mm and 2850 mm.
From these three bars you can cut the structure profiles:
- 2700 mm bar: n.3 600mm and n.2 450mm
- 2700 mm bar: n.6 450mm
- 2850 mm bar: n.1 600mm and n.5 450mm
Step 1: base with supports
| qty | part name | description/notes |
| 4 | Aluminum profile 30x30 450mm | |
| 8 | Internal bracket (Bosch 3842535577) | |
| 19 | Plexy support | File:Plexy-support.stl |
Take n.4 30x30 extrusions length 450mm.
Insert the plexiglass support (3d printed) in the profile grooves like:
Step 2: base with internal brackets
Create a square with profiles and add the internal brackets, one each end of profile
Check out the correct placement of Internal Brackets:
Step 3: Vertical structure
| qty | part name | description/notes |
| 4 | Aluminum profile 30x30 600mm | |
| 8 | Plexy support |
Tap M8 one side of 600mm vertical profile. Repeat 4x
Step 4: tighten base with column
Link the base with the vertical profiles. Check that these dimensions are equal with a caliper, then light tighten the screws.
Step 5: insert supports in the column
Insert two plexiglass supports for each column.
Repeat for every column. Total n.8 supports.
check photo:
Step 6: lower Z profile / Z motor mount
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 4 | Plexy support | |
| 2 | Internal bracket | Bosch 3842535577 |
| 1 | Z stepper plate | File:Z-stepper plate.PDF |
| 2 | M6 T-head bolt | Bosch 3842523921 |
| 2 | T-nut | Bosch 3842523925 |
Put two plexiglass supports on the upper side and two on lower side:
Mount the Z stepper plate in the mid of the profile:
Using two M6 T-head bolts and two T-Nuts.
TIP: measure 185mm from the edge of the profile.
Place two internal brackets at the end of the profile:
Place the profile in the structure with a distance of 46 mm from the base profile ( between the internal sides):
Step 7: front middle profile
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 5 | Plexy support | |
| 2 | Internal bracket | Bosch 3842535577 |
Take the mid profile for the front side and insert in one groove three plexy supports and two internal brackets:
Fix it and leave a gap of 85 mm between this profile and the lower one:
Step 8: right middle profile
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 5 | Plexy support | |
| 2 | Internal bracket | Bosch 3842535577 |
Take the profile for the right middle side and insert two plexy supports and two internal brackets:
Fix it and leave a gap of 85 mm between this profile and the lower one:
Step 9: left middle profile
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 5 | Plexy support | |
| 2 | Internal bracket | Bosch 3842535577 |
Take the profile for the left middle side and insert two plexy supports and two internal brackets:
Fix it and leave a gap of 85 mm between this profile and the lower one:
Step 10: Upper Z backside profile
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 2 | Internal bracket | Bosch 3842535577 |
| 7 | Plexy support |
Place one plexiglass support in each backside columun:
In the Upper Z profile put three supports upside and two downside.
Put the internal brackets at the end of the profile:
Fix it with a distance equal to 342 mm between the internal vertical surfaces of z-upper profile and mid profile on the rear side:
Step 11: Backside Top profile
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 2 | Internal bracket | Bosch 3842535577 |
| 5 | Plexy support | |
| 2 | M3 square nut |
Take two supports and insert a M3 square nut.
Insert one support in the left side (see photo) and another one in the right side:
Put three plexy supports and two internal brackets in the aluminum profile :
Mount the profile in the backside:
Step 12: Top Right profile
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 2 | Internal bracket | Bosch 3842535577 |
| 6 | Plexy support |
Per side insert two plexy supports in the vertical strut. Total four supports
Put two plexy supports in the aluminum profile and two internal brackets:
Mount the profile in position:
Step 13: Top Left profile
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 2 | Internal bracket | Bosch 3842535577 |
| 6 | Plexy support |
Do the same as step 12 but for left side.
Step 14: Top Front profile
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 2 | Internal bracket | Bosch 3842535577 |
Put two internal brackets:
Mount the profile in position:
