FuseBox
Release status: working
| Description | An affordable aluminum-framed CoreXY printer.
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FuseBox is a cheap CoreXY 3D printer that uses an aluminum extrusion frame.
Contents
Goal
To design an affordable, RepRappable 3D printer using CoreXY kinematics that offers high speed and quality.
Features
- Aluminum structure based on Misumi 1515 extrusions and printed brackets
- Uses a stacked variant of CoreXY that eliminates belt crossing
- Total materials cost under $350
- 210x160x200mm build area
- Capable of 0.5mm layer height and 100 mm/s printing
- Mostly RepRappable parts and easily hackable/upgradeable
- Provision for direct and Bowden extruder setups (Bowden currently preferred due to frame rigidity issues)
- Low moving mass—all motors stationary except extruder motor in direct-drive version
- Portable—all hardware and electronics (except for filament spool) are integrated within the frame
- No specialized tools or equipment necessary for assembly
Bill of Materials
Printed Parts
A zip file containing all the printed parts can be found here: File:FuseBox Printed Parts.zip
Other Parts
| Item | Quantity | Note | |
| 1515 Extrusion 380mm | 4 | ||
| 1515 Extrusion 330mm | 2 | ||
| 1515 Extrusion 345mm | 4 | ||
| 1515 Extrusion 330mm | 2 | ||
| 1515 Extrusion 240mm | 2 | ||
| M3x6mm Bolt | 96 | ||
| M3x10mm Bolt | 10 | ||
| M3 Nut | 100 | ||
| M5x25mm Bolt | 6 | ||
| M5 Locknut | 6 | ||
| 625 Bearing | 9 | ||
| 250mm M8 Threaded Rod | 1 | ||
| 300mm M8 Smooth Rod | 6 | ||
| LM8UU Linear Bearing | 4 | ||
| LM8LUU Linear Bearing | 4 | ||
| 5mm to 8mm Flex Coupler | 1 | Clamping type preferred to reduce wobble | |
| 2mm Pitch GT2 Belt 3m | 1 | ||
| 20 Tooth GT2 Pulley | 2 | ||
| Bed Leveling Springs | 4 | ||
| RAMPS 1.4 | 1 | ||
| Arduino Mega | 1 | ||
| NEMA-17 Stepper Motors | 4 | Tested with 76 oz-in steppers | |
| 12V LED Power Supply | 1 | Tested with a 30A supply | |
| 40mm 12V Fan | 2 | ||
| MK8 Drive Gear | 1 | ||
| Medium Binder Clip | 2 | Remove handles to use as extruder idler tensioners | |
| J-Head-compatible Hotend | 1 | Tested with Aluhotend V6; E3D support coming soon | |
| 8"x10"x 0.125" Glass Sheet | 1 | Used as a cheap and rigid PLA printbed; heated bed support not yet available | |
| Stick-on Furniture Feet | 4 | Optional | |
Development
Version 1.0
Initial variant. Uses a non-intersecting CoreXY design to eliminate belt crossing issues.
Issues
- Z-axis issues—slight wobble and linear bearing binding
- Slight rigidity issues caused by weak corner joints
- Extruder grip issues leading to inconsistent extrusion
- Untidy wiring
Todo
- Endstop integration (possibly with inductive z-probe)
- Cooling fan addition to improve bridging and top speed for small parts
- Bowden option for lower moving mass (will retain direct extruder for flexible materials)
- Diagonal aluminum braces on sides
- Reduce clearances for additional build area
Version 1.1
Changes'
- New compact extruder design with more solid hot end mount and fan duct addition
- Bowden extruder carriage designed; cold end still in development
- 608 bearing idler replaced by a 625 idler
- XY-gantry made more compact, resulting in ~18mm increase in maximum z-axis height
- Z axis changes: bar spacing reduced, additional reinforcement for z-nut crosspiece
Issues
- Slight z-wobble
- Rigidity
- 625 Idler breakage problem
Todo
- Additional bracing
- Endstop integration
1.1B
Uses a bowden extruder and replaces Aluhotend V6 with an E3D-Lite6. New idler design improves strength and extrusion consistency.
Version 1.2
Changes
- New Y Bar attachments using 1 bolt each
- Integrates bowden extruder and print fan
- Larger corner braces
- Cross braces on sides
- Endstop integration
- Added option for 30mm hotend cooling fan
- 10mm additional x-axis travel
Video
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Gallery
Top view of initial variant
Alternate view
First Print
Surface finish test with 0.1mm layer height
Perfect bridging after adding print fan
