Reprap Wilson Assembly Guide
Written by Martin Rice <mrice411@gmail.com>
++ For the latest version of this document, check the "docs" folder at +
++ https://github.com/mjrice/wilson +
++ +
++ Please refer to the wilson-bom spreedsheet for a comprehensive list of +
++ parts needed before you begin. +
++ +
++ You will find photos of most of the steps below indexed by the step +
++ number, located in the images/ folder. +
+
1. Assemble the Y axis (part 1)
1.1 Gather the following parts
1.4 Prep the Print Bed
-While the Y axis assembly is free, it is a good time to prepare the print bed which you will attach later.
+While the Y axis assembly is free, it is a good time to prepare the print
+bed which you will attach later.
Gather the following materials
d. The four linear bearing holders
e. Eight miniature zip ties
-
* Place the heat bed circuitboard over the wood bed and mark the four
corner locations with a pencil.
* Put the heat bed circuitboard aside and place the four linear bearing
mount with a line that is approx 10mm from the back edge of the bed.
* Mark all the holes for the bearing holders with a pencil.
* Remove the wood print bed and drill all the holes you marked with a 5mm
- drill bit. (You want the holes a little over-sized so that there is some
- room for the screws to "float" when you attach the bed).
-* Attach the linear bearing holders to the Y axis linear bearings with zip ties.
+ drill bit. (You want the holes a little over-sized so that there is
+ some room for the screws to "float" when you attach the bed).
+* Attach the linear bearing holders to the Y axis linear bearings with
+ zip ties.
Set the prepared wood print bed aside.
two nuts on each extrusion and attach the braces with a total of 8 M5
screws. Note that the longer extrusions (the "sides" of the frame)
should cover the ends of the bottom extrusion piece. Leave the screws
- loose until all 8 are started. Stand the frame "upright" to ensure the
- sides are slid down flush with the bottom and alternately tighten until
- all the screws are tight.
+ loose until all 8 are started.
+* Stand the frame "upright" to ensure the sides are slid down flush with
+ the bottom and alternately tighten until all the screws are tight.
* Rotate the frame so the other side is facing you and put it back flat
on your work surface.
* Slide two more T nuts into each side piece and attach the motor mounts
* You should have four T nuts sliding around between the lower corners,
which will be used to attach the Y axis to the frame in the next step.
+
3. Mount the Y axis to the frame
3.1 The following parts are used during this step:
a. The two plastic X end pieces ("motor" and "idler")
b. Eight linear bearings (LM8UU)
c. The two X axis smooth rods
- d. Two M5 nuts
+ d. Two M5 nuts
+ e. X endstop limit switch
+ f. One M3 x 30mm screw and nut
+ g. One spring
4.2 Hardware Assembly
* Using pliers, gently press an M5 nut into the provided insert in each
end.
* Place two linear bearings on each of the smooth rods.
+* Insert the X endstop switch (previously wired) into the slot provided
+ on the X motor end. Route the wires down and through the guide on
+ the bottom side of the end. Secure with a zip tie.
+* Press an M3 nut into the bottom of the Z axis adjuster, then thread
+ an M3 x 30mm screw through a spring and into the nut from the top side.
* Press each X end onto the pair of smooth rods, being sure to orient
them so that the M5 nuts are on the same side of the rods.
and SMART electronics mount.
e. Four M5 x 8mm screws
-5.2
+5.2 Assembly
* Insert two t-slot nuts into the top side of the aluminum extrusion.
* If you will be using the filament holder, rotate the extrusion 90
degrees and insert two more t-slot nuts into the top side.
* Insert the remaining t-slot nuts into the side opposite from the one
you started with.
-
-5.3
-
* Attach the upper Z axis mounts to the ends of the extrusion, tightening
the M5 nuts just until snug. Be sure to keep the two t slot nuts for
the filament holder on the "top" and the t slot nuts for the SMART
end until the threaded rods rest against the Z axis motor shafts.
* Tighten the z axis couplers.
-7. Mount X and Y motors
+7. Completing the Frame Assembly
-7.1 In addition to the frame from the previous step, you will need:
+7.1 Mount X and Y motors
+
+* In addition to the frame from the previous step, gather the following:
a. Two NEMA17 stepper motors
b. Two belt pulleys
- c. The two idler bearings and mounts
+ c. The two idler bearings and plastic bearing guides
d. Three M3 x 10mm screws
e. Three M3 x 14mm screws
- f. Two screws with lock nuts for mounting the belt idlers (probably M3 x 25mm)
+ f. Two M4 x 20mm screws and nuts
+
+* Mount the motors to the X and Y axis motor mounts using three screws
+ each.
+* Fit a pulley on each motor shaft and tighten the grub screws to keep
+ them secure.
+* Snap an idler bearing into each pair of plastic bearing guides, then
+ attach the idlers to the opposite ends of the X and Y axis from where
+ you attached the motors. Don't overtighten the screws that hold on
+ the idlers.
+
+7.2 Attach print bed
+
+* You will need:
+
+ a. The print bed you prepared earlier.
+ b. Eight M3 x 14mm screws and an equal number of M3 nuts and washers.
-* Mount the motors, the pulleys, the idlers.
-* Mount the print bed you prepared earlier to the Y axis bearing holders
- using Eight M3 x 14mm screws and an equal number of M3 nuts and washers.
- The washer should go on the screw first, which should go downward
- through the wood print bed and bearing holder, and secured with a nut.
- Attach each screw only loosely first, then check that the bed slides
- smoothly back and forth along the Y axis. Tighten the nuts a little at
- a time until secure.
+* Mount the print bed to the Y axis bearing holders. The washer should
+ go on the screw first, which should go downward through the wood print
+ bed and bearing holder, and secured with a nut. Attach each screw only
+ loosely first, then check that the bed slides smoothly back and forth
+ along the Y axis. Tighten the nuts a little at a time until secure.
-7.2 Attach the X carriage.
+7.3 Attach the X carriage.
-You will need:
+* You will need:
a. The printed X carriage
b. Eight miniature zip ties
+* Attach the X carriage with the belt guide "up" and with the flat
+ surface (where you will attach the extruder) toward the front of the
+ printer (the Y idler end).
+
+7.4 Attach Belts
+
+* You will need:
+
+ a. The X axis drive belt
+ b. The Y axis drive belt
+ c. The Y belt holder
+ d. 8 Miniature zip ties
+
+* Thread the X axis belt into place and secure with four zip ties (two
+ on each side of the extruder, trimmed short after tight).
+* Turn the printer over or have a friend hold it upside down, being
+ careful not to lift by or put pressure on the X axis rods.
+* Thread the Y axis belt into place. Hold the belt tight and use as a
+ guide for placing the Y belt holder. The leading edge of the belt
+ holder should be approximately in the middle of the wood print bed.
+* Mark the holes for the Y belt holder, then set the holder and belt
+ aside and drill the two holes with a 4-5mm hand drill.
+* Attach the Y belt holder with the head of the screws to the bottom,
+ with a washer and nut on the wood side.
+
+7.5 Attach accessory mounts
+
+* You will need:
+ a. Filament holder mounts
+ b. SMART display mounts
+ c. RAMPS electronics frame mount
+ c. Eight M5 x 8mm screws
+
+7.6 Attach heat bed
+
+* You will need:
+
+ a. The heat bed circuitboard
+ b. Four M3 x 30mm screws and locknuts
+ c. Four springs (approx 1" long uncompressed)
+
+* This is a good time to attach the heat bed thermistor if you have not
+ already done so. Depending on your heat bed and thermistor, the most
+ likely procedure here is to secure the thermistor to the middle of the
+ bottom-side of the heat bed with a strip of Kapton tape.
+* Attach the heat bed with a screw through each corner, with the head of
+ the screw up, down through the heat bed, through a spring, then through
+ the wood print bed, and into a lock nut. Compress the springs about
+ halfway (you will adjust each corner later to level the bed more
+ precisely).
+
+7.7 Attach Limit Switches
+
+* You will need:
+
+ a. Three micro limit switches
+ b. The Z axis limit switch mount
+ c. One T-slot nut and M5 x 8mm screw
+ c. M2 x 16mm screws and nuts as needed (up to 6 each)
+
+* If your limit switches do not already have wires attached, do that
+ now. You will need approximately 45cm (18") of wire on each switch
+ (depending on where you locate the electronics).
+
+* Slide a T nut into the outer side of the left upright piece from
+ the bottom. Attach the Z endstop holder with a M5 x 8 screw.
+
+8. Extruder Assembly and Mounting
+
+8.1 Assemble the Extruder
+
+* You will need:
+
+ a. The extruder body and idler.
+ b. The hot end.
+ c. The M8 Hobbed bolt
+ d. Two M8 nuts (or one M8 locknut), and washers (probably 4).
+ e. Two springs (approx 1" long uncompressed)
+ f. The M8 x 20mm smooth rod (or M8 x 20mm grub screw)
+ g. Three 608 bearings
+ h. Two M3 x 60mm screws
+ i. The larger extruder gear.
+ j. Three M3 x 30mm screws
+ k. Five M3 nuts
+
+* If your hot end was not previously assembled (heater resistor and
+ thermistor), do that now. Follow the instructions for your particular
+ hot end.
+* Slide the M8 x 20mm shaft through a 608 ball bearing then push this
+ assembly inside the extruder idler. You may have to use pliers to snap
+ the shaft into place. Apply even pressure on top of the shaft/bearing
+ to avoid cracking the plastic idler.
+* Insert an M3 nut into the inner recess provided on the idler. Use
+ pliers or a hot iron to fix the nut into place (be careful not to break
+ the idler in the process).
+* Thread an M3 x 30mm screw through the outer side of the idler on the
+ side you just inserted the nut, just until the screw starts into the
+ nut.
+* Fix the idler assembly to the Wade Body Extruder and then finish
+ screwing the M3 x 30 bolt all the way through the fulcrum support.
+
+* Slide the Wade Big Gear through the hobbed bolt so that the hex head of
+ the bolt is secured in the recess of the big gear. Slide 3-5 M8 washers
+ onto the bolt (they go between the gear and the body of the extruder to
+ provide spacing) followed by one 608 bearing. Insert the bolt into the
+ extruder body, securing the bearing in the hole provided. Add another
+ 608 bearing on the loose end of the bolt, followed by another M8 washer
+ and locknut. Tighten the lock nut just enough to keep the hobbed bolt
+ in place; it should spin freely.
+
+* Insert two M3 nuts in their slots on the top of the extruder body.
+ Place an washer, then spring, then another washer on each M3 x 60mm
+ screw, then thread the screws through the slots of the idler and into
+ the nuts you inserted in the extruder body. Tighten the screws until
+ the springs are well compressed (this keeps tension on the printer
+ filament). If either spring is too short (or the bolts are too long)
+ to compress properly, remove the bolt and place an M3 nut on first
+ (before the washer/springs).
+
+* Insert the hot end into the 16mm hold on the bottom of the extruder.
+
+* Secure the hot end to the extruder body by threading in two M3 x 30mm
+ screws through the front of the extruder (they will pinch the sides of
+ the hot end on their way through the plastic body). Secure with M3
+ nuts and tighten well (it is critical that the hot end be rigid and
+ not wobbly).
+
+8.2 Connecting extruder to X-axis
+
+* You will need:
+
+ a. Extruder assembly
+ b. Wade Small Gear
+ c. One NEMA 17 motor
+ d. The plastic fan duct.
+ e. One 40mm x 40mm x 10mm fan.
+ f. Four M4 x 25 mm screws
+ g. Four M4 nuts
+ h. One M3 x 30mm screw
+ i. Seven M3 x 14mm screws
+ j. Three M3 washers
+ k. One M3 x 8mm screw
+ l. Five M3 nuts
+ m. One M3 locknut
+
+* Insert two M4 nuts in the bottom of the extruder body in the slots
+ provided. Use pliers to gently press the nuts into the plastic, or
+ press them in with the tip of a hot soldering iron if the holes are
+ too tight.
+* Insert two M4 nuts into the slots on the sides of the extruder body.
+* The extruder is held to the X carriage by the four M4 x 25mm screws.
+ Insert the four screws through the back of the X carriage and then
+ slide on the extruder assembly (thread the top two screws into the
+ nuts you just inserted). Then screw the two lower M4 nuts into
+ place and tighten all four screws.
+* Insert an M3 nut into the slot on the small gear. Use pliers or a hot
+ iron to press into place if necessary.
+* Slide the small gear onto the shaft of the NEMA 17 motor. If
+ necessary, drill out the shaft hole on the small gear with a 5mm drill
+ bit.
+* Insert the M3 x 8mm screw and tighten against the shaft of the motor.
+* Place the motor assembly against the Wade Extruder Body (supply wires
+ upwards). Insert three M3x14 mm screws and three Ø3 mm washers without
+ tightening. Slide the motor assembly against the Wade Big Gear and
+ tighten the screws to hold the motor secure.
+* Attach the 40mm fan to the fan duct using four M3 x 14mm screws and
+ M3 nuts. Make sure the fan is oriented so that airflow is going toward
+ the duct (usually this means the side of the fan with a label on it
+ will be against the fan duct).
+* Fix the Fan Duct assembly on the Wade Extruder Body with an M3 30mm
+ screw and an M3 lock nut. Do not overtighten.
+
+8.3 Install glass bed
+
+* Now is a good time to install the glass bed. Place the glass on top
+ of the heat bed and secure with four paper-binder clips. If the X axis
+ is too low, you may have to manually turn the two Z axis rods to lift
+ it high enough so that the glass will fit underneat the hot end nozzle.
+
+9. Connect the Electronics
+
+* You will need:
+
+ a. The electronics controller of your choice (e.g. RAMPS)
+ b. The power supply
+ c. SMART display (optional)
+
+* Use the checklist below as you connect the electronics. If your
+ electronics board has multiple options for connecting devices, make a
+ note of which connection you use so that you can input the settings
+ to your firmware.
+
+ [ ] X axis stepper motor
+ [ ] Y axis stepper motor
+ [ ] Z axis stepper motors (2)
+ [ ] Extruder stepper motor
+ [ ] X axis limit switch
+ [ ] Y axis limit switch
+ [ ] Z axis limit switch
+ [ ] Heat bed power
+ [ ] Extruder heater power
+ [ ] Extruder fan power
+
+
+
+
+
+
+
+
+
HCoop / clinton / wilson.git / blobdiff