HackerBot Build Manual
Contents
- 1 Before You Begin
- 2 Downloads
- 3 Assembly Instructions
- 4 Electronics
Before You Begin
If you are here probably you are going to build an Hackerbot and we are glad to help you in case of trouble. Just drop an email at [email protected]
Right now documentation is very basic and our advice is to use Solidworks to see how printer has been designed.
Before starting out make sure to look at HackerBot BOM
Downloads
Project files are on GitHub:
- Stable release GitHub
- Developer unstable release are on the edge branch
If you have question, doubts, requests just ask ([email protected])
Assembly Instructions
Before assembling a HackerBot, make sure you have all the parts necessary. For the bill of materials, see HackerBot BOM.
Aluminum Frame
Base structure
| qty | part name | description/notes |
| 4 | Aluminum profile 30x30 450mm | |
| 8 | Internal bracket (Bosch 3842535577) | |
| 11 | Plexy support |
Step 1: base with supports
Take the four 30x30 structure profile of length 450mm. Insert the plexiglass support (3d printed) in the profile grooves in the following manner:
- three supports on three profiles
- two supports on the last one profile
Step 2: base with internal brackets
Create a square with profiles and add the internal brackets, one each end of profile
Check out the correct placement of Internal Bracket:
Columns
| qty | part name | description/notes |
| 4 | Aluminum profile 30x30 600mm | |
| 8 | Plexy support 3mm |
Step 3: tap M8 vertical strut
Tap M8 one side of 600mm vertical profile. Taps are for printer rubber feet
Step 4: tighten base with column
Link the base with the vertical profiles. Check that dimension are equal with a caliper and tighten the screws.
Step 5: insert supports in the column
Insert two plexiglass support in one column. The supports are only on internal face
Repeat for every column.
check the photo:
check out: total 8 plexyglass supports.
Mid plane profiles
| qty | part name | description/notes |
| 4 | Aluminum profile 30x30 450mm | |
| 23 | Plexy support 3mm | |
| 8 | Internal bracket | Bosch 3842535577 |
| 1 | Z stepper plate | File:Z-stepper plate.PDF |
| 2 | M6 T-head bolt | Bosch 3842523921 |
| 2 | T-nut | Bosch 3842523925 |
Step 6: lower Z profile / Z motor mount
Put two plexiglass supports on the upper side and two and lower side:
Mount the Z stepper plate in the mid of the profile:
Using two M6 T-head bolt and two T-Nut.
TIP: measure 185mm from the edge of the profile.
Place two internal bracket at the end of the profile:
Place the profile in the struct with a distance of 46 mm from the base profile:
---
Step 7: front middle profile
Take the mid profile for the front side and insert in one groove three plexy supports and two internal brackets:
Fix it and leave a gap of 85 mm between this profile and the lower one:
Step 8: right middle profile
Take the profile for the right middle side and insert two plexy supports and two internal brackets:
Fix it and leave a gap of 85 mm between this profile and the lower one:
Step 9: left middle profile
Take the profile for the left middle side and insert two plexy supports and two internal brackets:
Fix it and leave a gap of 85 mm between this profile and the lower one:
Upper Z profile
| qty | part name | description/notes |
| 1 | Aluminum profile 30x30 450mm | |
| 2 | Internal bracket | Bosch 3842535577 |
| 3 | Plexy support 3mm |
Step 10: Upper Z backside profile
Place one plexiglass support in each backside columun:
In the Upper Z profile put three supports upside and two downside.
Put the internal brackets at the end of the profile:
Fix it with a distance equal to 342 mm between the internal vertical surfaces of z-upper profile and mid profile on the rear side:
Top square structure
| qty | part name | description/notes |
| 4 | Aluminum profile 30x30 450mm | |
| 8 | Internal bracket | Bosch 3842535577 |
| 20 | M6 T-head bolt | Bosch 3842523921 |
| 20 | T-nut | Bosch 3842523925 |
| 9 | Plexy support 3mm |
Step 11: Top Backside profile
Take two supports and insert a M3 square nut.
Insert one support to the left side (see photo) and other one to the right side:
Put three plexy support in the aluminum profile and two internal brackets:
Mount the profile in the backside:
Step 12: Top Right profile
Per side insert two plexy support in the vertical strut. Total four supports
Put two plexy support in the aluminum profile and two internal brackets:
Mount the profile in position:
Step 13: Top Left profile
Do the same as step 12 but for left side.
Step 14: Top Front profile
Put two internal brackets:
Mount the profile in position:
XY systems
Support plates
| qty | part name | description/notes |
| 1 | Front right support plate | File:Support plate 50x50 L.80mm Front-Right.PDF |
| 1 | Front left support plate | File:Support plate 50x50 L.80mm Front-Left.PDF |
| 1 | Back right support plate | File:Support plate 50x50 L.140mm Back-Right.PDF |
| 1 | Back left support plate | File:Support plate 50x50 L.140mm Back-Left.PDF |
| 20 | M6 T-head bolt | Bosch 3842523921 |
| 20 | T-nut | Bosch 3842523925 |
Step 15: Back Right plate
Using four M6 T-head bolt fix in the corner the support plate:
Step 16: Back Left plate
Using four M6 T-head bolt fix in the corner the support plate:
Step 17: Front Left plate
Using two M6 T-head bolt fix in the corner the support plate:
Step 18: Front Right plate
Using two M6 T-head bolt fix in the corner the support plate:
XY system
Step 19: Cubic Slider
| qty | part name | description/notes |
| 4 | Cubic slider | |
| 8 | Cubic slider belt clamp | 3D printed |
| 24 | M3x12 screw kit | |
| 4 | Cubic slider PTFE bushing |
Assemble the cubing slider:
and take care when inserting the PTFE bushing. If possible use a 8mm reamer after.
Step 20: XY Shafts
| qty | part name | description/notes |
| 2 | Shaft 8mm. length 465mm | |
| 2 | Shaft 8mm. length 438mm | |
| 8 | GT2 20 teeth pulley (8mm bore) | |
| 8 | Shim | POM / Delrin |
| 8 | 608 Bearings | |
| 8 | Bearing housing | 3D printed |
| 32 | M3x16 screw kit | fixes the bearing supports with support plates |
Using the cubic slider assemble the shafts as in photo:
double check:
- the correct orientation of Cubic slider's
- shafts should not be touching the Supports plate
- Cubic slider's should be running well on the shafts, and shafts should turn easily
DON'T tighten the screws.
Step 21: XY Belts
| qty | part name | description/notes |
| 4 | GT2 open belt length 830mm | XY core belts |
Place the four belts like as show below:
DON'T pull the belts.
Step 22: XY Motors
| qty | part name | description/notes |
| 2 | Stepper motor Nema 17 | 2.5A (or 1.7A), shaft 5mm |
| 2 | GT2 20 teeth pulley | 5mm bore |
| 2 | GT2 20 teeth pulley | 8mm bore |
| 1 | GT2 closed belt 77 teeth | SDP-SI.COM (6R51M077060) |
| 1 | GT2 closed belt 66 teeth | SDP-SI.COM (6R51M066060) |
Y Motor (right side)
Use a GT2 closed belt 66 teeth:
X Motor (backside)
Use a GT2 closed belt 77 teeth:
Step 23: XY Motor belt tighteners
| qty | part name | description/notes |
| 1 | Belt Tightener | with screws and 624zz bearing |
| 1 | Belt Tightener short | with screws and 624zz bearing |
Head
| qty | part name | description/notes |
| 2 | Shaft 8mm length 370mm | Head shaft support |
| 1 | Head v2 | File:Head v2 FAN.stl File:Head v2 fan support 60.stl |
| 4 | Linear Bearing | LM8UU |
| 2 | Pneumatic fittings | |
| 4 | M3x8 grub screw | fixes the hotends |
| 4 | M3x25 | fixes the hotends |
Z system
| qty | part name | description/notes |
| 1 | Z Stepper plate | |
| 1 | Z Stepper motor | nema 17 1.7A |
| 1 | Z Stepper motor screw kit | 4x M4x20 screws, 4x M4 washer |
| 4 | SK10 Shaft support | 10mm shaft |
| 10 | Collar nut (Bosch 3842523925) | used for stepper plate and SK10 |
| 10 | T-Bolts (Bosch 3842523920) | used for stepper plate and SK10 |
| 1 | Motor-Trapezoidal screw coupler | flexible coupling 5 mm and 8 mm diameter |
| 1 | Trapezoidal screw 12x3 length 410mm | length: 410mm, 398mm threaded |
| 2 | Z shaft 10mm length 390mm | |
| 2 | LM10LUU | 10mm linear bearing with housing |
| 1 | LM10LUU screw kit | 8x M5x20 screw, 8x M5 washer |
| 1 | Print area support L-shaped | |
| 1 | Trapezoidal nut | |
| 1 | Aluminium heatbed support | |
| 4 | Springs | |
| 1 | Z endstop holder | |
| 1 | Z endstop tuning | |
| 1 | Z endstop knob | |
| 1 | Z endstop spring | |
| 1 | Collar nut (Bosch 3842523925) | used for Z endstop holder |
| 1 | T-Bolts (Bosch 3842523920) | used for Z endstop holder |
| 1 | M4 threaded rod length 60mm | |
| 1 | Mechanical Z endstop |
Take the stepper motor for the z-axis and join the motor shaft toward top to stepper plate with the screws and washers (stepper motor kit of this section checklist).
On the other side of the stepper plate, add to the motor shaft (5mm of diameter) the flexible coupling.
Now, join the free side of 8mm diameter of the coupling with the cylindrical part of the trapezoidal thread.
Widen the holes of shaft supports to 6mm of diameter, to allow the connection with the profiles trough M6 T-head bolt. Join the shaft support to the mid-rear and upper z profiles with T-head bolts.
Now take the L-shaped plate, fasten with this the linear bearings through M5 screws (Linear bearings must be placed on the internal side of L-shape) and, on the other side, the trapezoidal nut through M4 screws.
Then screw the trapezoidal thread in the brass nut attached to the L-shaped plate. Therefore insert the two shafts in the holes of L-shaped plate and of supports, in the end fasten their screws to block the axis.
Printing area
- 1x Heatbed 200x200mm
- 1x Heatbed glass
- 4x Heatbed spring
- 4x M3x30 screw
- 8x M3x30 washer
- 1x Aluminium Heatbed support 225x280x5 mm
- 5x M5 screw, 5x M5 nut, 10x M5 washer
The Heatbed must be connected with the Aluminium Heatbed support keeping a distance between them, this gap will be calibrated later.
To reach this goal, insert the four M3 screws in the heatbed holes with a washer between head screws and hot plate. On each threaded side, add a washer and a spring. Now fasten the 4 screws in threaded holes of Aluminium Heatbed support keeping a distance between this and the hot plate, as above mentioned.
Finally, connect all this things assembled on the L-shaped plate of Z-system through the five holes close together using the M5 screws, nuts and washers.
Assembling Base Metal sheet
- 1x Base metal sheet, 1.5 mm of thickness
- ?? 4x M6 T-head bolt Rexroth code 3842523921, 4x M6 nut
- Use supports to place it at the bottom of the printer
Extruder
Extruder is mounted on a plate (1.5mm thick) on the back of Hackerbot
PTFE bowden tube is 3.18mm inner diameter, 6mm outer diameter and total length of one bowden tube is 750mm
Wade-Greg Tilt extruder
extruder to bowden tube needs an adaptor: http://www.thingiverse.com/thing:180259
Hotend
THead
JHead
Door
| qty | part name | description/notes |
| 1 | Door Plexy | |
| 2 | Aluminum profile 20x20 length 408mm | |
| 2 | Aluminum profile 20x20 length 384mm | |
| 4 | Cubic joint 20x20 2 way | Bosch 3842524484 |
| 2 | Hinge | Bosch 3842544526 |
| 1 | Handle | ? |
Create a square with the four 20x20 profiles, in the vertex insert the cubic joints. The shorter profiles of 383mm will be vertical with the door assembled. On one of the profile of 383 mm assemble one side of the hinge, then put all on the front-right column. Insert plexyglass
Electronics
BOM
- 1x Switching power supply DC 12v - 25A
- 2x Power supply clamps (aluminium or printed)
- 4x M3x10 screws, 2x M3 nuts, 2x M3 washer
- 1x RUMBA (R.eprap U.niversal M.ega B.oard with A.llegro driver)
- 1x RUMBA printed box
Endstop
| qty | part name | description/notes |
| 1 | X end stop holder | 3D printed |
| 1 | Y end stop holder | 3D printed |
| 2 | micro switch / end stop | length of their two cables : about 90 cm |
Controllers
- RAMPS
- RUMBA
- to do: DUET
Drivers
- Pololu A4988 stepper driver
- DRV8825 (Kliment design: cooldrv r2)
Motors
- Wantai / Longs Stepper motor 2.5A or 1.7A
Wiring for RUMBA are:
| MOTOR | CABLE (LiYY 4x0.25) | RUMBA connector |
| BLACK | Brown | 1B |
| GREEN | Green | 1A |
| RED | Yellow | 2B |
| BLU | White | 2A |
LCD Controller
- RRD LCD XXL LCD
Power Supply
- Switching power supply 350W 24V
