Prusa i3 Build Manual

Prusa i3 Documentation

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Boxed style Frame Style

In the future this page might contain a tutorial. Until then, a tutorial for the boxed frame style Prusa i3 by Kliment:

http://78.47.92.212/i3_documentation_pics/

http://koti.kapsi.fi/~kliment/photos/i3/
http://koti.kapsi.fi/~kliment/photos/prusa3/

http://www.flickr.com/photos/prusajr/8127635345/in/photostream

Box Frame Version Rods:

X Axis;

2x 470mm 8mm smooth rod

1x 20mm 8mm smooth (for extruder idler, use 8x20 threaded rod or grub screw instead as substitute)

Y Axis:

2x 470mm 8mm smooth rod 2x 500mm M8 threaded rod 4x ~200mm M8 threaded rods

Z Axis:

2x ~370mm M5 threaded rod 2x 405mm (or 400mm) 8mm smooth rod for Z

(you could play with the Z lengths to increase building height) (Note that you need longer wood cuts for 4 of the 450x100mm plates; add n to both wood (450+n)x100 and all Z axis rod length)

Single Sheet Frame Style

http://www.flickr.com/photos/prusajr/8107645350/in/photostream

There is no tutorial for the Single Sheet Frame style Prusa i3; however the X axis, X carriage, and Y frame and bed are mostly the same.

The Prusa3 repository (below) includes frames for both aluminum and laser cut wood (sized for 6mm thick) for both the "single_plate" and "mini" variants. The wood frame files include two braces, which stabilize the frame from flexing. Photos of each can be found at:

"single_plate": http://www.flickr.com/photos/sbgraber/sets/72157632513929965/with/8378333341/
"mini": http://www.flickr.com/photos/sbgraber/sets/72157632518684272/with/8379471692/

The Prusa3ALU-*.dxf and Prusa3WOOD-*.dxf feature y-carriages that use zipties to fasten three LM8UUs to the underside. Prusa3_SC10UU-*.dxf has mount holes for SC10UU linear bearing blocks. Use whichever carriage fits your need.

Github:
https://github.com/josefprusa/Prusa3 - Josef Prusa - main development repository
https://github.com/alexrj/Prusa3/tree/i3-unterwelt - Sound MINI repository
https://github.com/EiNSTeiN-/Prusa3/ - EiNSTeiN - 608 bearings, compact dual extruder repository

Build Documentation:
http://78.47.92.212/i3_documentation_pics/
BOM:
http://www.ethercalc.org/wcrkzrngtw
Build Videos:
http://www.youtube.com/watch?v=NixSNAUPciQ
Rod Lengths:
http://titanpad.com/bU77NESnMC

JBFromOZ - notes preparing to build an aluminium frame prusa i3.

Prusa i1/i2 smooth rod lengths should be usable for an i3 single-plate reprap.

Instructions on the github say to RP each part in the single-plate folder. I believe this instruction applies to the box frame version only, some items need more than 1 copy.

It is not yet 100% clear which extruder to use, there is a dual extruder and a compact extruder in the branch though neither looks complete. there is also a Greg's adapter in the /mini/extruder/greg-wade folder, it uses the nuts_and_bolts.scad which needs to be copied to the openscad library folder.

I am planning to use a MGS extruder with a Nema17 stepper, designs from Sound are shown from his i3-unterwelt branch

Build photos from EiNSTieN's build record, including some additional reference to his edits for 608 bearings, GT2 belts, dual extruders etc.

Y PCB Aluminium frame is connected to LM8UU's with zipties, no RP parts required (as per nateplate style attachment)

Description	Qty	Image
RP Parts		located in Prusa/single_plate folder
z-axis-top.scad	1
z-axis-bottom.scad	1
y-motor.scad	1
y-idler.scad	1
y-corners.scad	4
y-belt-holder.scad	1
x-end-motor.scad	1
x-end-idler.scad	1
x-carriage.scad	1
magnetic-holder.scad (used for hall effect sensors / endstops)	2
fan-mount.scad	1
belt-guide.scad (suit 623 bearing)	4
Extruder options		not complete documentation at this stage
gregs-wade.scad (in box_frame/extras folder)	1 (???)
greg-adapter.scad (in mini/extruder/greg-wade folder)	1 (???)
dual-extruder.scad (deprecated - experimental)	1 (???)
compact-extruder.scad (experimental - likely to be replaced by nema17 extruder)	1 (???)
EiNSTeiN branch		master branch of i3 single-frame parts by EiNSTeiN: master at https://github.com/EiNSTeiN-/Prusa3/
platter.scad (EiNSTeiN variant) single plate for i3	1
compact-extruder.scad (EiNSTeiN variant) dual extruder in build log images below	1
MGS Extruder T2.5 Belts		MGS branch of i3 single-frame parts bySound: i3-unterwelt at https://github.com/alexrj/Prusa3/tree/i3-unterwelt
mgs-body.stl	1
mgs-groovemount_ABS.stl	1
mgs-idler.stl	1
mgs-mount.stl	1
x-carriage.stl	1
Single-Frame i3		Aluminium 6mm plate 370mm x 370mm
Prusa3ALU-FREZOVANY-v4.dxf	1

Build by pictures.

Description	Image
build Y assembly using 4 corners, Y motor mount, Y Idler mount, bearing rods, 8mm nuts washers.
Clean and de-burr aluminium 6mm plates., tap holes as required
Cable tie LM8UU's to Y carriage, and attach Y belt connection.
Attach Z mounts to Aluminium plate.
Attach Z steppers and smooth rods. Install LM8UUs into the X Carriage (not onto rods as pictured)
build X carriage and attach to ali plate
attach Y assembly to ali plate
attach and tension Y belt.
Attach and tension X belt.
Attach Heated Bed.
build extruder assembly (dual extruder based on EiNSTeiN's branch as per above in these pictures)
Attach Ramps (standoffs etc as shown)
Complete all wiring!
Attach Extruder
Dual Printers!
Dual Extrusion!

Further specific details refer to wiring diagrams and other construction references on this wiki.

BOM

belt guide bearings x 2 some use 623's some use 624's the Ø4 holes can suit 624 but some modification or finding the right copy amongst the githubs listed above may be required at this stage i3 rods BOM

Single plate Version Rods:

X Axis;

2x 370mm 8mm smooth 1x 20mm 8mm smooth (for extruder idler, use 8x20 threaded rod or grub screw instead as substitute)

Y Axis;

4x 205mm 8mm threaded 2x 320mm 8mm smooth 2x 345mm 10mm threaded

Z Axis;

2x 320mm 8mm smooth 2x 320mm 5mm threaded

NEMA17 steppers x 5
J-Head MkV x 1
GT2 pulleys x 2
GT2 belts x 2
(Note that MGS files in Sound's i3-underwelt branch is stl's with T2.5 belts assumed)
clear tubing (z coupling) x 2
Z drives M5 (length) x 2