MendelMax

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MendelMax

Release status: working, but needs user feedback.

MendelMaxPlaceholder.jpg
Description
A true reprap; printed brackets, with the rigidity of aluminium extrusions.
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CAD Models
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MendelMax is a new RepRap 3d printer designed by Maxbots. It is a true reprap, using printed brackets, but instead of using threaded rod for the structural elements it uses inexpensive aluminium extrusions. This gives a huge increase in rigidity for a minimal extra cost (Self sourcing will cost about $50 more than a standard Prusa when purchased from the recommended suppliers). The required extrusions are available world wide from a variety of suppliers. For those that watch the KickStart page, these extrusions are the result, of the MakerRod project, and are T-slot designs which simplify construction by allowing bolt-together Construction.

A sister project is just getting started extending the Mendel Max to make the bed wider for consumer products. It currently doesn't have its own page, and mostly involves expanding the X-axis, and the frame in the X direction. The standard width of a Mendel Max X direction extrusion is 300mm the new one would be 1000mm (Approx. 1 meter) Since the MakerRod is much stiffer, it should be able to be extended without flexing more than the current Prusa does. The standard BOM would simply need some substitutions to get larger extrusions. Substitutons for the 4 300mm and 2 of the 420mm extrusions would have to be made, the latter for about 1012mm to allow for the Prusa Z-axis stepper mounts, and to extend the X-axis rods.

Also see: The GitHub for SCAD-Files (N.B as in python-FreeCAD) and Scaling


In addition to greatly increased rigidity, this design is faster to assemble (probably 4 hours for most users), a larger (and more easily scaled) build area (~215x235x190 if built at the standard dimensions), easier to print, and easier to hack on.

Files (.stl's) are found for now at MendelMax thingiverse page. For full assembly instructions and BoM lists see its homepage.

Vitamins:
Quantity Description Type Size (mm) Comments
6 20x20mm Aluminium Extrusions 420 See: suppliers-list
4 20x20mm Aluminium Extrusions 340
4 20x20mm Aluminium Extrusions 300
100 Xmm (slot sized) T-slot Nuts -
100 Screws Fastener M5 or 10mm Small list on various suppliers.
100 Washers Fastener M5 or 10mm Cheapest available.
6 Nuts Fastener M8 or 5/16" Plain or stainless steel, not zinc coated.
2 Screws/bolts Fastener M8 or 5/16" 25mm/1" long
4 Bearing Bearings 608ZZ
2 Rod Smooth Rod 8mm×420mm X-bar (Required: 3pcs á 1m)
N.B: 304 Stainless Steel or A2 Tool Steel are recommended for smooth rods as it can help to prevent friction from rust and manufacturing (straightness) standards are higher. Rust issues can be prevented on the normal steel rods by maintaining a coat of oil. The smooth rods can also be cut from larger 3x1m pieces (see Smooth Rod Cut Order below).
1 T5-Timing Belt 900mm×5mm X-axis. Length needs confirmation.
1 T5-Timing Belt 840mm×5mm Y-axis. Length needs confirmation. (Also have a look at this page regarding 'choosing belts and pulleys'.)
2 Rod Smooth Rod 8mm×406mm Y-bar
2 Rod Smooth Rod 8mm×350mm Z-bar
2 Lead axis Threaded Rod 8mm×210mm Z-bar
5 Bipolar Stepper Motor NEMA 17 Have a look these suppliers.
2 Spring 8mm ID to eliminate backlash in the z axis
1 Calibration Straight object 234mm For frame alignment. Hardly needed, especially if the supplier cut the length for you.
1 Calibration straight object 290mm Dito.
1 Electronics + endstops Brains This can be RAMPS, Sanguinololu, Gen6, Gen7, Gen3, or any other Mendel compatible electronics. Endstops are either optical switches or microswitches (Recommended) or a Reed switch as Hall-0 and you need three, one for each of the X, Y, Z axes.

Smooth Rod Cut Order (when cutting from 1m lengths):

 Rod 1: 420mm, 420mm 
 Rod 2: 406mm, 406mm
 Rod 3: 350mm, 350mm