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Step by Step Assembly.md 21.73 KiB

Build Instructions

The build instructions below are divided into two parts, namely pre-assembly and final assembly. In the pre-assembly some of the sub-assmeblies or parts are either prepared or assembled together to ease the final assembly. The number in the (#) paranthesis denotes the quantity of the part required. (PA) stands for pre-assembly

Hardware

Button Head Cap Screw (BHCS) Socket Head Cap Screw (SHCS) DIN 433 Washer Teethed Idler Pulley
BHCS have a button shaped head with a hex slot and require an allen wrench SHCS have a cylindrical head with a hex slot and require an allen wrench DIN 433 shims are washers with a consistent thickness made by cutting and so can be used as spacers between idler pulleys Teethed idler pulley has free rolling bearings and the toothed side of a timing belt moves on it
Smooth Idler Pulley Drive Pulley Heatset Insert Set Screw
Smooth idler pulley has free rolling bearings with the smooth side of the backside of a timing belt moves on a smooth idler pulley Drive pulley sits on a motor shaft and is always teethed. Comes with two set screws that need a allen wrench to tighten the pulley onto the shaft Heatset inserts have ridges on the outside and a female thread on the inside. They are pressed into printed parts using a soldering iron Set screws are headless screws with external threads and a hex key on one side. Found on drive pulleys and in the L brackets to join two aluminium profiles
L bracket Corner Bracket Hammer nut
L bracket is an L shaped connector with 2 set screws, used to connect two T-nut profiles at a right angle. The L bracket sits within the T-slots of a profile and so is concealed Corner Bracket are aluminium connectors that connect profiles on the plane. Each angle corner bracket requires 2 SHCSs and 2 hammer nuts Hammer Nut are placed inside the slot within a profile and a bolt is screwed on the other side

*** Tools ***

Allen Wrench Flat Head Screwdriver Cross Head Screwdriver
Allen wrench is a tool with a hex head to tighten srews with a hex slot Flat head screwdriver is a tool to tighten flat head screws which are found on the electronic wire terminals of the controller board Cross head screwdriver is a tool to tighten cross head screws and found on the controller board with electronic wire terminals

Prepare printed parts

Z-axis lower mounts (2)

Z-axis upper mounts (2)

x

Frame

Z-axis lower mounts

Z-axis linear rods

Build Platform

Z-axis upper mounts

Y-axis Left and Right

X-axis

Parts required

  1. XY Idler Assembly Left (1)
  2. XY Stepper Motor Bracket (1)
    1. Nema 17 Motor (1)
    2. GT2 20T Drive Pulley (1)
    3. M3x8mm SHCS (1)
    4. M3x10mm SHCS (2)
  3. 10mm dia 340mm long Smooth Rod (1)
  4. LMW10U Bearing (1)

1. XY Idler Left and Right

Parts required

  1. XY Idler Assembly Left (1)
    1. Printed XY Idler - Left (1)
      1. M3 Nut (2)
      2. M3x20mm bolt (1)
        1. M3x30mm bolt (1)
      3. 3mm Bore GT2 Pulleys (2)
      4. M3 shim washer (4)
      5. Tool #2.5 Allen Wrench

Before and After Assembly

Before Assembly After Assembly

Exploded view of XY Idler

Step 0 - Prepare parts required for build

  1. Printed XY Idler bracket - Left (1)
  2. M3 Nut (2)
  3. M3x20mm bolt (1)
  4. M3x30mm bolt (1)
  5. 3mm bore GT2 Pulley (2)
  6. M3 shim washer (4-5)
  7. Allen wrench #2.5


Step 1 - Insert 2x M3 nuts into printed XY Idler bracket

Step 1 - Insert M3 nuts into slots Step 1.1 - M3 nuts inserted

Step 2 - Insert 2x M3 bolts into printed XY Idler bracket

  • Insert the M3x20mm bolt till the end but do not tighten now. It will be tightened in a later step when the 10mm smooth rod is inserted
  • Insert the M3x30mm bolt only halfway through
Insert M3 bolts M3 bolts inserted

Step 3 - Insert first teethed idler pulley

  • The teethed idler has a bore diameter of 3mm and width of 6mm
Insert Idler pulley Pulley inserted

Step 4 - Insert M3 Shim Washers

Insert 4xM3 shim washers Washers inserted

Step 5 - Insert second teethed idler pulley in SHCS

Insert 2nd teethed idler pulley Insert M3x30mm SHCS till end

Step 6 - Tighten M3x30mm SHCS

  • Screw in and slightly tighten the M3x30mm SHCS with an 2.5mm allen wrench
  • Caution! Do not tighten to the point that the pulleys cannot spin freely!
Tighten Bolt with allen wrench Finished XY Idler assembly

Step 7 - Assemble XY Idler Right

The XY Idler Right is a mirror copy of the XY Idler Left asembly. The required components are the same. The only difference is that the XY Idler printer XY Idler Right is a mirrored version of the XY Idler Left.

Repeat steps 0 - 6 for the XY Idler Right assembly

2. XY Stepper Left and Right

Parts required:

  1. Printed Stepper Motor Bracket - Left (1)
  2. M3 Nut (1)
  3. M3x20mm bolt (1)
  4. Nema 17 Motor (1)
  5. GT2 20T Teethed 5 mm Bore Drive Pulley (1)
  6. M3x8mm bolt (1)
  7. M3x10mm bolt (2)

Exploded view of XY Stepper

Before and After Assembly

Before Assembly After Assembly

Step 1 - Insert M3 nut into printed stepper motor bracket

Step 2 - Insert M3x20mm SHCS but do not tighten so as to deform plastic

Step 3 - Place bracket on Nema17 motor

Step 4 - Insert M3 Bolts and tighten

1.3 Subassembly - Y-axis smooth rod insertion

Parts required:

  1. 340mm long 10mm dia smooth rod (1)
  2. Pre-assembled XY Idler Bracket Left
  3. Pre-asssembled XY Stepper Bracket Left

Step 1 - Insert 10mm dia 340mm long smooth rod into the XY Idler Left and XY Stepper Left

Step 2 - Tighten the M3x20mm SHCS on the XY Idler bracket till the 10mm smooth rod is fixed in place

Step 3 - Tighten the M3x20mm SHCS on the XY Stepper Bracket till the 10mm smooth rod is fixed in place

2. Y-axis Right Pre-assembly (1)

Repeat the same process as in Y-axis pre-aassembly Left. The XY Idler Right and XY Stepper Right are mirrored versions of the XY Idler Left and XY Stepper Left.

3. Build Platform Pre-assembly

Parts Required

  1. 2020 Profile 335mm long (2)
  2. 2020 Profile 140mm long (2)
  3. Printed Corner Brackets (4)
    1. M5x8mm Bolt (2)
    2. M5 Hammernut (2)
  4. Z-Axis Bearing Holder (4)
    1. M5x10mm Bolt (4)
    2. M5 2020 Hammer Nuts (4)
    3. LM8UU Bearing (2)
  5. Z Nut Bracket (2)
    1. M5x10 Bolts (4)
    2. 2020 M5 Hammer Nuts (4)
    3. Trapezoidal Lead Screw Nuts 8mm (1)
    4. M3x12 Bolts (4)
    5. M3 Nut (4)
  6. Bed Bracket (4)
    1. M5x10 Bolts (2)
    2. M5 2020 Hammer Nuts (2)
    3. M3x40 Bolts with Springs (1)
    4. M3 Hand Tightening Nuts (1)

4. Z-axis lower mount (2)

Parts required

  1. M3x25 Bolts (2)
  2. M3 Nut (2)
  3. M5x10 Bolts (4)
  4. M5 Hammernut (4)

5. Z-axis upper mount (2)

Parts required

  1. M3x25mm bolt (2)
  2. M3 Nut (2)
  3. M5x10 Bolts (4)
  4. M5 Hammernut (4)

6. Y-Carriage Pre-assembly (2)

Parts required

  1. Y-Carriage Printed Part (1)
  2. M3 Heatset Insert (4)
  3. M3 Nut (4)
  4. M3x14mm bolt (2)
  5. M3x30mm Bolt (2)
  6. GT2 20T Teethed 3mm Bore Smooth Idler Pulley (1)
  7. X-End Stop Flag (1)

Instructions:

  1. Insert

7. X-carriage Pre-assembly (1)

  1. Printed X-Carriage (1)
  2. M3 Heatset Insert (10)
  3. M3x14mm Bolt (4)
  4. 3mm dia 12mm long Dowel Pins (4)
  5. LM8UU Misumi Bearing (3)

8. Extruder Mount Pre-Assembly (1)

  1. Printed Extruder Mount (1)
  2. M3 nut (4)
    1. Insert 2 nuts for extruder motor mount
    2. Insert 2 nuts for retainer bracket mount
  3. X-axis Endstop Assembly (1)
    1. Printed X-endstop holder (1)
    2. Mechanical micro-endstop switch (1)
    3. 26G/24G Wire 4cm long (2)
    4. 2pin JST-XT Female Connector (1)
  4. M3x6mm bolt (1)

9. Exhaust Pre-assembly (1)

Parts required

  1. Exhaust Housing (1)
  2. M3 Heatset insert (7)
  3. PTFE Tube Through Connector (1)
  4. 6020 Fan (1)
  5. M3x12mm bolt (4)
  6. Exhaust Grill (1)
  7. Exhaust Mount Bracket (2)
  8. Carbon Filter (2)
  9. Fan Mount (1)