Thursday, 7 February 2013

Prusa i3 Physical Build (part 2)

Made some more progress with the build.

Connected up the belts on the X Axis:
Close up of Motor end, the metal T2 Gear came with the motor:
 Close up of X Carriage:
The Belt is T2 and about 740mm long, it is a continuous belt that came out of a printer I scrapped, you can just about make out the fold in the belt in the middle of the X carriage.

Another salvaged continuous belt, again T2, and again folded in the middle to avoid cutting it.
Z Axis M5 leadscrews installed:
This pretty much completes the physical build.

Power supply mounted to the frame:
This is a 203W XBox 360 power supply, good for 16.5A at 12V, obtained for £5.00 + P&P from Ebay, also came with RGB leads, which I can either use or sell on. This power supply should be more than enough for the heated bed as well as all other electronics.

I dismantled it, then drilled 4 holes through the case to mount it to the frame, then put it back together again in-situ.

You can just make out the other end of the power cable, where I cut off the XBox connector and ferrite core, so I can solder up the various 12V and GND cables.

I also extracted the ferrite core from its plastic molding, so can put that back over the cable to help reduce unwanted interference from the power supply.

I have also started on the wiring for the motors. I have only completed the X, Y and Z motor wiring so far, as well as mounting the Sanguinololu to the frame.

The wire is 6 core alarm flex from Wickes, £9.99 for 50m, this should be enough wire for many, many projects.

I am only actually using 4 cores, and pulling out the other 2, so I can use these elsewhere as required.

Monday, 4 February 2013

Prusa i3 Physical Build

I finally started cutting up the shelving boards from Homebase, and contrary to what it says on their website, they are not made of MDF, they are in fact made of chipboard.

I have my own cutting list, which is not quite the same as the one used in the BOM, but based on my own slightly reduced frame size:

6 x 430x110
2 x 430x110
1 x 460x110
1 x 220x220.

Likewise the threaded rods are custom lengths:

2 x M8 x 440
4 x M8 x 180

Smooth rod lengths are the same as for a standard Prusa:

2 x 8 x 420
2 x 8 x 405
2 x 8 x 350

I forgot to take any pictures of cutting or assembling the frame, but did remember to take a few of the main assembly.

Front end of Y frame:
Rear end of Y frame:
Y frame rectangle:
 Y rectangle with build plate attached:
 X Axis:
 X Axis and Z axis attached to frame:
 Almost complete physical build:
I still have to attach the belts for the X and Y Axes, and the threaded rod for the Z Axis.

In all about half an hour to cut the wood, another half hour to assemble the frame, then an hour or two to assemble the rest.

Next step will be to connect up the motors to the Sanguinololu board, and see how well it moves.