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Prusa Mendel

Main Body

Printed Parts

Quantity Description Type Comments Diagram
2 coupling RP Pm-coupler.jpg
3 endstop-holder RP Pm-endstop-holder.png
1 x-carriage RP Pm-x-cariage.jpg
1 x-end-idler RP Pm-x-idler.jpg
1 x-end-motor RP Pm-x-motor.jpg
1 y-motor-bracket RP Pm-y-motor-bracket.jpg
2 z-motor-mount RP Pm-z-motor.jpg
4 belt-clamp RP Pm-belt-clamp.jpg
8 bar-clamp RP Pm-bar-clamp.jpg
2 rod-clamp RP Pm-rod-clamp.jpg
2 pulley RP Pm-pulley.jpg
4 frame-vertex with foot RP Pm-frame-vertex-foot.jpg
2 frame-vertex RP Pm-frame-vertex-footless.jpg
12 pla-bushing RP-PLA check your build file, the file makes either 4 or 12 Pm-bushings.jpg

Non-Printed Parts ("vitamins")

Quantity Description Type Comments
Required
83 M8 nut Fastener Buy a 100-pack to be on the safe side. M8nut.jpg
93 M8 washer Fastener Buy a 100-pack to be on the safe side.
6 M8×30 mudguard / fender washer Fastener
2 M4×20 bolt Fastener To mount the extruder
2 M4 nut Fastener To mount the extruder
2 M4 washer Fastener To mount the extruder
22 M3×10 bolt Fastener
16 M3×25 bolt Fastener Or eight M3×25 bolt plus eight M3x20 bolts. The M3x25 bolts are too long for the recent Prusa z-motor-holder and rod-clamp, and also for the Z motor couplings. See Section 8, steps 4 and 13 for details.
4 M3×40 bolt Fastener
70 M3 washer Fastener
40 M3 nut Fastener 8 optionally locknut / stop nut / nyloc
2 M3 grub screw / set screw Fastener M3x8 seems about ideal but anything 6mm or longer should do. If these are hard to get, additional M3×10 bolts will do the job instead.
3 608 roller skate / inline skate / skateboard bearing Bearings
4 ballpoint pen springs Spring To fit over M3 bolts. Ballpoint pens are a common, cheap source of suitable springs. They are about 25mm long and compress to about 10mm.
6 M8×370mm Threaded rod 3 per side

Note: The threaded rods can be cut from larger 6x1m pieces (see Threaded Rod Cut Order below).
4 M8×294mm Threaded rod front / rear
3 M8×440mm Threaded rod top / bottom
2 M8×210mm Threaded rod Z-leadscrew
1 M8×50mm Threaded rod or M8x30 or longer bolt for X idler. Take care: if the bolt is too long, it may not be threaded along a sufficient length
2 8mm×420mm Smooth rod X-bar

Note: 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).
2 8mm×406mm Smooth rod Y-bar
2 8mm×350mm Smooth rod Z-bar
1 225mm×225mm print top plate Thick Sheet
1 140mm×225mm print bottom plate Thick Sheet
1 840mm×5mm T5 pitch timing belt Belt Y axis
1 900mm×5mm T5 pitch timing belt Belt X axis
4 NEMA 17 bipolar stepper motors Stepper Be sure to get ones with at least 20mm of shaft length. Shorter shafts require modifications to the X pulley assembly and Z motor couplers.
50 small cable binder / ziptie Misc
1 Electronics + endstops This can be RAMPS, Sanguinololu, Gen6, Gen7, Gen3, or any other Mendel compatible electronics. Endstops are either optical switches or microswitches (Recommended), and you need three, one for each of the X, Y, Z axes.
Optional
3 30mm×10mm Optoflags Thin Sheet if using opto endstops
2 8mm ID spring Spring to eliminate backlash in the z axis
1 object with precisely 290mm length for frame alignment
1 object with precisely 234mm length for frame alignment

Note: You can combine the latter two by having a piece of thick sheet with dimensions 290mm×234mm. Make sure to mark which side is which.

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

 Required: 6x1m Long 8mm Threaded Rods (or 5x1m pieces + 1x50cm piece)
 
 Rod 1: 370mm, 370mm, 210mm, ~50mm (The last piece will end up somewhat shorter than 50mm. )
 Rod 2: 370mm, 370mm, 210mm, ~50mm ( Use it for your idler. Alternatively, an M8x30 or     )
 Rod 3: 370mm, 294mm, 294mm, ~42mm ( longer bolt can be used.                              )
 Rod 4: 370mm, 294mm, 294mm, ~42mm
 Rod 5: 440mm, 440mm, ~120mm
 Rod 6: 440mm

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

 Required: 3x1m Long 8mm Smooth Stainless Steel Rod 
 
 Rod 1: 420mm, 420mm 
 Rod 2: 406mm, 406mm
 Rod 3: 350mm, 350mm

The Prusa Mendel uses the 4 drivers in the standard Mendel electronics package to drive 5 motors by using two steppers wired in parallel to one driver [1].

Extruder

Printed Parts

Quantity Description Type Comments Diagram
1 extruder block RP M8_Extruder_Block_3.stl M8-extruder-block-3.jpg
1 extruder idler block RP M8_Extruder_Idler_Block_2.stl 50px
1  ? RP 11t17p.stl 50px
1  ? RP 39t17p.stl 50px

Non-Printed Parts

Quantity Description Type Comments
Feeder
2 608 bearings, skateboard bearings Bearings
1 M8X50 bolt Fastener to be hobbed, M8x60 has a longer smooth part, allows a second lock-nut, and may be easier to find
1 M8 nut Fastener Nyloc works better, but a pair of nuts will also work
4-5 M8 washers Fastener to space the large gear clear of the motor retaining bolt heads
Idler
1 608 bearing, skateboard bearing Bearings
1 (M)8X20 Threaded rod
4 M4X60 or M4X45 hex head bolts Fastener Hex head will work best (they won't turn), and longer than 45 mm will be easier to assemble if you can find them.
4 M4 nuts Fastener typically wing nuts
8 M4 washers Fastener
4 ~4mm ID springs Spring Sized to fit over an M4 bolt, unsprung length of 10-12mm, each spring providing 25-35N load. For a given filament drive force, you'll need about twice the spring force - i.e., if you want 100N of filament drive, your springs need to push with about 50N each.
16 M4 washers Fastener optional; 4 washers on each M4X45 idler bolt between the main block and the idler block will limit the idler travel and make reloading filament easier.
NOTE: Some users have their extruders working without springs, but springs are recommended. A good source for these springs is in the cloth-cabinet on spring loaded skirt-hangers or trouser-hangers. Just cut the right length off the springs.
Hot End Mount
2 M3X35 bolts Fastener
4 M3 washers Fastener
2 M3 nuts Fastener
1 2.5mm drill See section Hot End
Stepper Motor Mount
3 M3X10 bolts Fastener Low profile bolt heads might work better here
3 M3 washers Fastener
1 M3 grub screw Fastener To secure the pulley, ideally 8mm long, but anything 6mm+ should be fine
1 M3 nut Fastener To secure the pulley
Stepper Motor
1 NEMA 17 bipolar stepper motors Stepper 5 kg*cm works well; Kysan 42BYGH4803 is what I used. Should be capable of creating a holding torque of at least 40Ncm, at the very least.
Extruder Mount
2 M4X20 bolts Fastener
2 M4 nuts Fastener
2 M4 washers Fastener