Prusa i3 Blomker
Release status: working
Description | Prusa i3 Variant by Blomker Industries
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Prusa i3 by Blomker Industries
This page describes the Prusa i3 variant put together by Blomker Industries. This is the Single Plate Aluminium version running on SCV10UU linear bearing for Y Axis. A very sturdy and rigid setup.
Josef Prusa is the designer of Prusa i3. We love his work for the way he design 3D Printers with minimalist concept.
Design
We have incorporated some of our ideas into the original Prusa i3 design. Some of the enhancements area :
- Direct Drive Extruder Carriage. Download here:Thingiverse:181015
- Glass corner bracket for a PLA Only machine. Download here : Thingiverse:193663
- Dual option for Y Axis Linear Bearing - SCV8UU, SCV10UU, SC8UU, SC10UU are supported
Specifications
- Print Area Dimensions: 200mm x 200 mm x 155 mm
- Maximum Print Speed: 150mm/sec
- Minimum Print Layer Height: 0.1mm or 100microns
- Frame: 5083 Aluminium 6mm thick, 10mm diameter galvanised threaded rod
Links
Assembly Instructions
Before you start, please take note of the following :
- Do not exert excessive force when tightening bolts and nuts on the printed parts. The printed parts may crack.
- Never connect/disconnect stepper motors when powered on. The stepper drivers may be damaged if you do so.
- Double check the polarity of power supply wiring before powering on for the first time. Reversed polarity will damage the controller board.
- Make sure that the fan is constantly blowing at the hot end's aluminium barrel. Operating the printer without extruder fan can cause filament to jam in the barrel.
Tools required : X Acto Knife, Flat Head Screwdriver, a pair of 17mm Spanner, a set of Metric size Allen Key
2pcs of 10mm diameter smooth rods and 4pcs of SCV10UU Linear Bearings
Slide in two pieces of SCV10UU into each 10mm smooth rod. Do this gently to avoid knocking loose the tiny ball bearings.
Print bed and 8pcs of M5 x 10mm cap screws
Attach the print bed onto the SCV10UU with the M5 cap screws
Y belt holder, 2pcs M3x16mm cap screws, 2 M3 nut
Attach the Y belt holder to the center of print bed using the M3 cap screws
Tighten the M3 nuts at the bottom
2pcs of 10mm threaded rods, 4pcs of M10 washer, 8PCS of M10 nut. Prepare them as shown in the picture.
X End printed parts, 2pcs of M5 nut, 4pcs of LM8UU bearing
Insert the LM8UU bearings into the X End bearing holders as shown in picture. Knock them lightly into position if required.
Expanding the bearing holder with a screw driver may help.
Push the M5 nuts into the nut trap as shown (see yellow arrows)
Cut off the tiny bit of plastic on all 4 Z Axis corners
This allow the plastic to expand a little more for 8mm smooth rods to be inserted
All 4 Z Axis corners, M3 x 16mm cap screws and M3 nut
Mount the lower Z corners as shown
Tighten the M3 nut at the back
Picture shows all 4 corners mounted but please mount only the bottom one for now.
2pcs of NEMA 17 stepper motor and 2pcs of flexible motor shaft coupler
Mount the motors onto the Z corner with M3 x 10mm cap screws
Mount a GT2 pulley up side down as shown in the picture
Secure the stepper motor onto the X End Motor Holder with M3 x 12mm cap screws
Assemble the 624ZZ on the X End Idler as shown. M4 nut not required to secure the assembly.
Insert the 5mm threaded rods 1/4 way through
3pcs LM8UU & 2pcs 8mm dia x 378mm smooth rods. Insert the bearings as shown
Insert the 300mm length smooth rods for Z Axis through the LM8UU bearings at both X Ends. Be careful and gentle when doing this. Insert it straight to avoid knocking the tiny bearings inside LM8UU out of its position.
Push the 378mm smooth rods into the X End (with motor mount). Push them all the way in. Knock lightly if required.
Notice that the 2 LM8UU bearings should be above.
Push the other X End in. Knock lightly if required
Insert the Top Z Axis smooth rod holder (left side)
Insert the Top Z Axis smooth rod holder (right side)
Place the partially assembled Z Axis stage onto the frame. Both the 5mm threaded rods should be inserted to the shaft couplers. The Z Axis smooth rods should be inserted to the hole on the Motor Holder. Make sure the smooth rods' end are seated on the motor's top surface.
Make sure both the 5mm threaded rod and 8mm smooth rods are seated in position
Make sure both the 5mm threaded rod and 8mm smooth rods are seated in position
Secure both the Top Z Axis Smooth Rods Holder to the frame using 2pcs of M3x16mm cap screws and 2pcs of M3 nut for each holder.
Tighten the grub screws on shaft coupler to grip the 5mm threaded rods
Prepare the X Carriage by inserting zip ties as shown
Tighten the zip ties around the LM8UU bearings as shown
Place the glass surface on top of the heat bed. Secure it using bulldog clips.
Raise the Y Idler until the belt is in tension. Make sure belt is not sloppy. Tighten the M10 nuts to hold the Y Idler in position for belt tensioning.
Mount the hot end fan as shown. This fan is very important to cool the hot end's heatsink barrel.
M4 & M3 nuts pushed into nut traps
M4 x 8mm cap screws to secure the hotend mount onto extruder carriage
Extruder lever arm, 623ZZ bearing, 12mm set screw
Break the support structure in bearing slot with a screwdriver
Insert the 624ZZ bearing and set screw
Mount the assembled extruder to the carriage using 2pcs of M3 x 10mm cap screws
The only calibration required is to ensure that the starting height for Nozzle tip is just slightly above the print surface when the Z Axis is homed. The nozzle height should look like the picture in above when homed. Adjust the position of Z Endstop switch to increase/decrease the nozzle tip height. If it is too low, the nozzle tip will scrape across the print surface and damage the Kapton tape surface. If it is too high, the first layer of extruded plastic will not stick to surface.
Make sure the nozzle tip is at equal height across the entire print surface. The Y Axis (back to front) should not be a problem if the printer was assembled correctly. Adjust the X Axis (left to right) height by turning the Z Axis stepper motor shaft couplers by hand. Turn one side at a time to increase/decrease the height at one end. Slide the Extruder Carriage by hand from left to right to check on the starting height.
Wire up the Prusa i3 according to the diagram.
Download Software Pack :
Windows OS Platform http://www.blomker.com/Prusai3_Windows.zip
MAC OS X Platform http://www.blomker.com/Prusai3_Mac.zip
Software installation and operating guide included in the .zip file.