PonokoRepRap

*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.

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.

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.

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 at the end:

• PonokoExtruderAssembly
• PonokoXAxisAssembly
• PonokoCornerAssembly
• PonokoYAxisAssembly - photographed, not fully documented
• PonokoFrameBaseAssembly
• PonokoZFrameAssembly
• PonokoXAndYInstallation - not started yet

-- Main.VikOlliver - 20 Nov 2008