PonokoRepRap

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The "Ponoko" RepRap

*Under Construction*

Overview

This is a laser-cut RepRap (technically a RepStrap) very similar to the BitsFromBytes design but modified to be cut without any routing. It is designed to minimize the number of specialty and expensive components needed to construct a RepStrap. It uses exactly the same motors and electronics as a Darwin RepRap, and is capable of accepting alternative stepper motors and DC gear motors (all available from http://rrrf.org). The extruders are of an exchangeable design, and are directly compatible with a Darwin exchangeable extruder. This extruder is available from Diamond Age Solutions Ltd. (VikOlliver's company) or can be cut from the source files by a service such as [Ponoko|http://ponoko.com Ponoko].

Note that the RepRap and this RepStrap are part of a research project. This means it can be a bit of an adventure assembling one. This may put you off, or it may improve on the thrill you get from achieving a working machine.

Prerequisites

The lasercut kit from Ponoko does not include anything other than the structural plastic parts. You will need the electronics kit and motors in addition to the lasercut bits. We now have a Bill of Materials.

You will need a number of components to complete the building of the lasercut kit: a laser-cut kit (really), fastenings, basic tools and probably some way of repairing or re-fabricating broken parts. You will need about two square metres of bench space, decent illumination, and possibly aids for close-up work. We recommend a smoke detector in your workshop if one is not already fitted.

It helps to have already installed the the RepRap host software on your PC and the firmware on your electronics before you begin construction.

PonokoRepRap-dsc04302.jpg

Basic Rules

Do not force acrylic - it cracks. Do not tighten fastenings in acrylic more than is absolutely necessary - it cracks. Be very careful when moving your RepRap under construction, as an acrylic structure is fragile before it is fully braced - it cracks. You may spot a pattern emerging.

Do not throw anything away until the RepRap is assembled and working. You may need to fabricate replacement parts from them. Some of the parts come from the holes in other parts.

Do not separate parts until you need them. Do not take the paper off until you're ready to assemble them. Some parts need the paper. For ease of handling, you can split the large sheet in two. Locate a cut which threads its way through other parts approximately in the middle of the sheet. You can cut the top and bottom rails to extend the cut from edge to edge. Carefully cut the paper backing and you can separate them.

Do not allow small children to put the little bits of plastic that fall out in any bodily orifice. Or cats.

Do share your tips and improvements with everyone.

Assembly

The following pages deal with the assembly of the mechanics. If you start with the first one, it will link you on to the next and so forth:


  • PonokoExtruderAssembly:
    PonokoExtruderAssembly-dsc04349.jpg

  • PonokoXAxisAssembly:
    PonokoXAxisAssembly-dsc04290.jpg

  • PonokoExtruderSocketAssembly:
    PonokoExtruderSocketAssembly-dsc04263.jpg

  • PonokoXIdlerAssembly:
    PonokoXIdlerAssembly-dsc04218.jpg

  • PonokoRepRapXMotorAssembly:
    PonokoRepRapXMotorAssembly-dsc04235.jpg

  • PonokoCornerAssembly:
    PonokoCornerAssembly-dsc04257.jpg

  • PonokoZMotorAssembly:
    PonokoZMotorAssembly-dsc04423.jpg

  • PonokoUpperCornerAssembly:
    PonokoUpperCornerAssembly-dsc04438.jpg

  • PonokoYAxisAssembly:

PonokoYAxisAssembly-dsc04458.jpg

  • PonokoFrameBaseAssembly:
    PonokoFrameBaseAssembly-dsc04464.jpg


PonokoFrameBaseAssembly-dsc04483.jpg

  • PonokoZFrameAssembly:
    PonokoZFrameAssembly-dsc04513.jpg

  • PonokoFrameBracing:
    [[image:cache-><br clear=|thumb]]
  • PonokoYInstallation - in progress:
    PonokoYInstallation-dsc04536.jpg

  • PonokoBedChainFitting - in progress:
    PonokoBedChainFitting-dsc04559.jpg

  • Installing the X Axis - in progress:

PonokoRepRapXAxisAssembly-dsc04290.jpg


PonokoRepRapXAxisAssembly-dsc04575.jpg

Builders

  • RussNelson
  • VikOlliver

-- Main.VikOlliver - 29 Nov 2008