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 8mm smooth rod
- 1x 20mm 8mm 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 8mm smooth rods
- 2x 400mm M10 threaded rod
2x 400mm M8 threaded rods(M10 is actually correct)
- 4x 205mm M8 threaded rods
- 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; The plates are (Z rod length + 45mm) long
Default is 12mm thick wood. Get something that is robust! The thickness is mostly needed because you screw into the side of the wood.
- 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
Single plate Version Rods: - updated to numbers from https://github.com/josefprusa/Prusa3/blob/master/box_frame/doc/dimensions.md
- 2x 370mm M8 smooth
- 1x 20mm M8 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 M8 smooth - Note take care to cut to exactly same length.
- 2x 380mm M10 threaded - Note M10 is correct.
- 2x 320mm M8 smooth.
- 2x 300mm M5 threaded (or 320mm if you want it to protrude above the frame).
|M5 Threaded||M8 Smooth||M8 Threaded||M10 Smooth|
|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 rest of this section is for the EiNSTeiN variant BOM, which uses 608 bearings and no M8 threaded rods.
to build an Einstein variant (M10 for both Y axis, 608 idler bearings) you will need the following hardware:
- 34 x M10 washers (y frame)
- 34 x M10 nuts (y frame)
- 4 x M10 x 210mm threaded rod (y frame short)
- 2 x M10 x 380mm threaded rod (y frame long)
- 3 x M8 x 30mm bolts ( x y and z idlers, X idler may need head ground off, a screw cap hex bolt will fit without modification)
- 3 x M8 washers (X Y and Z idlers)
- 3 x M8 nylocs (X, Y, and Z idlers)
- 8 x M3 x 8mm socket cap bolts (6 for Z motor mounts, 2 for Y motor mounts)
- 16 x M3 washers (6 for Z motor mounts 2 for Y belt mount, 8 for bed mount to PCB)
- 4 x M3 nyloc nuts (bed mount to PCB)
- 4 x M3 x 20mm (bed mount to PCB)
- 5 x M3 x 10mm socket cap bolts ( 3 for X motor mounts, 2 for Y belt mount)
- 2 x 8mm x 320 smooth rods (Z smooth rods)
- 2 x 8mm x 350 smooth rods (Y smooth rods)
- 2 x 8mm x 370 smooth rods (X smooth rods)
- 2 x M5 x 300 threaded rod (Z axis)
- 2 x M5 nuts (Z axis drive nuts)
- 4 x M3 8mm standoffs (bed spacer above Y carriage to bed)
- 10 x LM8UU bearings (or equivalent) (3 for Y carriage, 3 for X carriage, 4 for X ends)
- 2 x M5 internal clear tube couplers for Z axis ( i used beer line)
this does not cover:
- cable ties - 2.5mm wide ones to fit through all the fixings
- RP parts - see images and links to sources below
- aluminium single plate frame with Y carriage - reprapsource.com, hotends.com, norcalreprap.com
- hardware for extruder, eg. the Metal Gear System Metal_Gear_System_Extruder kit from reprapsource includes all extruder hardware and mounting hardware)
- (Note that MGS files in Sound's i3-underwelt branch is stl's with T2.5 belts assumed)
- steppers - depending on whether the extruder uses a nema 17, 4 or 5 nema17 steppers.
- electronics, psu, pcb heat, belts, pulleys, the reprapdiscount and fabster3d ultra/ultimate kits are a good all in one source for ramps, PCB heater, LCD, GT2 belts and pulleys, thermistors, endstops, wiring (approx $200 inc shipping on ebay)
- hotend (J-heads are a good start, also arcol, magma, ceramic, prusanozzle, all are good options)
- PSU (either a modded ATX or dedicated 33A switchmode supply (approx $40 inc shipping on ebay)
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)|
|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||MGS parts at https://github.com/Joaz/machine_parts/tree/master/mgs_prusa|
|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
https://github.com/alexrj/Prusa3/tree/i3-unterwelt - Sound MINI repository
https://github.com/EiNSTeiN-/Prusa3/ - EiNSTeiN - 608 bearings, compact dual extruder repository, note that Y ends for M10 not M8 rods
https://github.com/Joaz/machine_parts/tree/master/mgs_prusa - Joaz - MGS extruder repository
Other Build Documentation
Single plate build pics: http://www.sub-design.co.uk/i3build/
Prusa i3 Frame Kit Build Manual by ReprapUniverse.com:
JBFromOZ - notes preparing to build an aluminium frame prusa i3.
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.
New Design complete laser cut kit assembly:
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!)
|build Y assembly using 4 x corners (RP), 1 x Y motor mount (RP), 1 x Y Idler mount (RP), 4 x M8 prusa and sound's repo (M10 einsteins repo) threaded rod short 2 x M8 sound's repo (M10Prusa and Einstein repos) threaded rod long, 2 x M3 x 8mm cap head bolts, (10mm perhaps with M3 washers) 34 x M8 nuts (see notes later), 34 x M8 washers (see notes later), 1 x stepper. Note that there are the following variants. Prusa's master branch has M10 2 x 380mm (12 nuts and washers) and M8 4 x 205mm (22 nuts and 22 washers) (210mm for nyloc) Sound's repo uses all M8. Einsteins Repo uses all M10. be aware which corners, idler and motor you print, as these are all affected!!!|
|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.|
|Another way of fixing bearings to the y-axis carriage (this way there is no risk of the ends crashing the vertical plate).|
|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 (with 6 x 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!|
Further specific details refer to wiring diagrams and other construction references on this wiki.