Prusa i3 Build Manual

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Prusa i3 Documentation

Main page | Prusa i3 Buyer's Guide | Prusa i3 Build Manual | Prusa i3 User Manual | Prusa i3 improvements

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:

http://78.47.92.212/i3_documentation_pics/

http://www.flickr.com/photos/prusajr/8127635345/in/photostream

Rods

X Axis;

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

Y Axis:

2x 470mm 8mm smooth rod
2x 500mm M8 threaded rod
4x ~200mm M8 threaded rods

Z Axis:

2x 405mm 8mm 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; add n to both wood (450+n)x100 and all Z axis rod length)

Frame

Default is 15mm thick wood. Get something that is robust!! The thickness is mostly needed because you screw into the side of the wood!

6x 450x100x15mm wood
1x (450+15)x(100+(15*2))x15mm wood (for the ppl that suck at math; thats 465x130x15mm wood)

Any wood _over_ 15mm thickness will not work for the bottom plate, the Y will then be lifted from the ground.
So if you are using thicker wood for the frame, this _will_ work, but be sure to _NOT_ use thicker wood than 15mm for the bottom plate of the frame.

Single Sheet Frame Style

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

Materials

Parts to be Purchased

Rapid Prototype Parts

Description	Qty	Image
RP Parts		located in Prusa/single_plate folder
z-axis-top.scad	1
z-axis-bottom.scad	1
y-motor.scad	1
y-idler.scad	1
y-corners.scad	4
y-belt-holder.scad	1
x-end-motor.scad	1
x-end-idler.scad	1
x-carriage.scad	1
magnetic-holder.scad (used for hall effect sensors / endstops)	2
fan-mount.scad	1
belt-guide.scad (suit 623 bearing)	4
Extruder options		not complete documentation at this stage
gregs-wade.scad (in box_frame/extras folder)	1 (???)
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 (???)
EiNSTeiN branch		master branch of i3 single-frame parts by EiNSTeiN: master at https://github.com/EiNSTeiN-/Prusa3/
platter.scad (EiNSTeiN variant) single plate for i3	1
compact-extruder.scad (EiNSTeiN variant) dual extruder in build log images below	1
MGS Extruder T2.5 Belts		MGS branch of i3 single-frame parts bySound: i3-unterwelt at https://github.com/alexrj/Prusa3/tree/i3-unterwelt
mgs-body.stl	1
mgs-groovemount_ABS.stl	1
mgs-idler.stl	1
mgs-mount.stl	1
x-carriage.stl	1
Single-Frame i3		Aluminium 6mm plate 370mm x 370mm
Prusa3ALU-FREZOVANY-v4.dxf	1

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:
https://github.com/josefprusa/Prusa3 - Josef Prusa - main development repository
https://github.com/alexrj/Prusa3/tree/i3-unterwelt - Sound MINI repository
https://github.com/EiNSTeiN-/Prusa3/ - EiNSTeiN - 608 bearings, compact dual extruder repository

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.

Build Instructions (With Pictures!)

Description	Image
build Y assembly using 4 x corners (RP), 1 x Y motor mount (RP), 1 x Y Idler mount (RP), 4 x M8 threaded rod short 2 x M8 threaded rod long, 2 x M3 x 8mm cap head bolts, (10mm perhaps with M3 washers) 36 x M8 nuts, 36 x M8 washers, 1 x stepper
Clean and de-burr aluminium 6mm plates., tap holes as required
Cable tie LM8UU's to Y carriage, and attach 1 x Y belt connection (RP), 2 x M3 x 10mm cap head bolts, 2 x M3 washers, 3 x LM8UU bearings 3 x cable ties, 1 x aluminium Y carriage.
Attach Z mounts to Aluminium plate. 2 x upper Z mount (RP), 2 x lower Z mount (RP) 10 x M3 x 10mm (mounts to ali plate)
Attach Z steppers and smooth rods. , 6 x M3 x 8mm Z motor to mounts (10mm with M3 washers). Install LM8UUs into the X Carriage (not onto rods as pictured)
build X carriage and attach to ali plate
attach Y assembly to ali plate
attach and tension Y belt.
Attach and tension X belt.
Attach Heated Bed.
build extruder assembly (dual extruder based on EiNSTeiN's branch as per above in these pictures)
Attach Ramps (standoffs etc as shown)
Complete all wiring!
Attach Extruder
Dual Printers!
Dual Extrusion!