Professional Documents
Culture Documents
An introduction
Steven Devijver
Copyright © 2011 Steven Devijver
Legal Notice
Introduction
How the printer works
Parts of the printer
1. Frame
2. Y-axis and bushings
3. Z-axis and Y-axis
4. Extruder
5. X-carriage
6. Print plate
7. Electronics
8. Stepper motors
9. Stepper motor controllers
10. End stops
Plastics
Tools and skills
1. Mechanical build
1.1. Wrenches and keys
1.2. Digital caliper
1.3. Spirit level
1.4. Plumb line
1.5. Installation of Z-axis bushings
1.6. Flat on motor shafts
2. Electronics build
2.1. Soldering
2.2. Cable stripper
2.3. DIY Sanguinololu build
RepRap software
1. Arduino software for RAMPS
2. Arduino software for Sanguinololu
3. Firmware
3.1. Downloading the Sprinter firmware
3.2. Configuring the Sprinter firmware to your electronics board
3.3. Uploading the Sprinter firmware to your electronics board
4. Skein software
5. Host software
5.1. Prerequisites for Windows
5.2. Prerequisites for other operating systems
5.3. Downloading Pronterface
5.4. Running Pronterface
6. Slic3r: alternative skein application
Buyer's guide
1. Printed parts
2. Vitamins
2.1. Electronics
2.2. Power supply
2.3. Stepper motors
2.4. Hardware kits
2.5. Extruder
2.6. Hotends
2.7. Kapton tape
Build instructions
1. X Y and Z axes calibration video
2. Printing spare parts
3. Selecting voltage for endstops on the Sanguinololu board
About this book
1. How to contribute
1.1. Overview
1.2. Create your free GitHub account
1.3. Fork the repository
1.4. Clone your copy of the repository
1.5. Making changes
1.6. Commit your changes
1.7. Push your changes
1.8. Create a pull request
2. Similar efforts
3. Contributors
Introduction
1. Frame
2. Y-axis and bushings
3. Z-axis and Y-axis
4. Extruder
5. X-carriage
6. Print plate
7. Electronics
8. Stepper motors
9. Stepper motor controllers
10. End stops
1. Frame
Image 2: empty RepRap Prusa Mendel frame. Notice the various
The frame gives the printer its stiffness. The three axes
of the robot will be added to this frame. The frame
consists of threaded rods connected together with
printed parts (these are called the vertices.)
RepRap: the printer that can print its own parts
The Rep in RepRap stands for reproduction. RepRap printers are
designed in such a way that they can print their own parts. As soon as
you’ve got your printer working you can print parts for a new printer or
you can start printing various improvements on the standard design.
RepRap owners regularly sell the printed parts required to build new
printers on ebay.
Apart from the vertices the frame also contains printed
parts to hold and control the Y-axis and Z-axis. On the
top left and top right you can see the printed parts that
will hold the stepper motors of the Z-axis.
Image 3: RepRap Prusa Mendel frame with smooth rods for Y-axis
(source)
4. Extruder
The RepRap Prusa Mendel is typically equiped with a
Wade’s geared extruder[3]. This extruder consists of
two parts: a cold top part that feeds the platic filament
and a hot bottom part that melts and extrudes the
plastic. These two parts are commonly called the Wade
extruder (the cold part) and the hot-end (the hot part).
Image 15: assembled X-axis with two smooth rods, the X-end
idler and X-end motor printed parts and the printed X-carriage
(source)
6. Print plate
Printed parts are printed on the print plate. The three
axes move together so that the nozzle can move above
the print plate in an area of 200mm wide by 200mm
deep by 100mm high.
The print plate actually consists of two plates: the
print bottom plate that is mounted on the X-axis
smooth rods with bushings or linear bearings and the
print top plate that is mounted on the bottom plate and
that forms the print surface.
The top print plate must be level! The top print
plate is mounted with fours springs slid over four
screws so that it can be easily adjusted. Image
17 shows both print plates one stacked on top of the
other. The springs are clearly visible. The bottom print
plate is mounted on the X-axis smooth rods with
printed bushings.
Image 17: top print plate stack on bottom print plate. The
section (source)
plate (source)
7. Electronics
The electronics board controls the printing process.
Several electronics options exist for RepRap printers
(they are all open-source.) Currently the most popular
are:
RAMPS, a DIY shield board for Arduino MEGA
Sanguinololu, an all-in-one DIY board with
microprocessor on board
The RepRap electronics board has several functions:
Process G-code instructions.
Control the four stepper motor controllers (there are
five stepper motors on a RepRap Prusa Mendel but
both Z-axis motors are connected to the same
stepper motor controller.)
Control the temperature of the hot-end and monitor
the hot-end thermistor.
Monitor the end-stops (end-stops are used for
homing the three axes, see later section.)
Control the temperature of the heated bed and
monitor the heated bed thermistor (the heated bed is
optional.)
The electronics board is connected to the PC using a
USB-to-serial converter. The Arduino used with the
RAMPS board has such a converter built-in, so does
the Sanguinololu board.
The RAMPS electronics board has been around
longer than the Sanguinololu and has seen regular
updates. RAMPS is a shield board that needs to be
connected to an Arduino MEGA 1280 or 2560 board
(or a clone board.) The RAMPS has these additional
features:
One extra heater / thermistor channel (three in total)
Optional SD card reader
Image 20 shows a RAMPS board mounted on a
Arduino MEGA board with four Pololu stepper motor
controller boards installed:
installed (source)
8. Stepper motors
There are five stepper motors on the RepRap Prusa
Mendel:
One to control the Y-axis
One to control the X-axis
Two to control the Z-axis
One to control the extruder
Normally all five motors on a printer are the same but
this is not required except for the two motors that
control the Z-axis: these must be identical. The
RepRap Prusa Mendel has been designed to use
bipolar NEMA17 motors. NEMA17 determines some
of the dimensions of a stepper motor.
Image 22: the internals of a stepper motor (source)
[ ]
2 You can find the X-axis parts with linear bearings
for a RepRap Prusa Mendel here.
[ ]
3 You can find the designs for the Wade's geared
extruder here
[ ]
4 Instructions for bamboo as heat barrier here.
[ ]
5 See this excellent guide for more details on warping
[ ]
6 See these instructions for building your own
heatbed
[ ]
7 Instructions on how to solder the small chip on the
Sanguinololu board
[ ]
8 See these instructions for loading the Sanguinololu
boot loader
[ ]
9 See here for details on how to etch a RAMPS board
yourself
[
10] This applet demonstrates how micro-stepping
works inside a stepper motor (note: the stepper motor
shown in this applet is unipolar while RepRap uses
bipolar motors. The principles however remain the
same.)
[
11] Source
Plastics
ABS and PLA are very different plastics and they each
require specific printer configurations. ABS is made
from petroleum and is more flexible than PLA. PLA is
biodegradable, is more rigid than ABS and will
dissolve in water. ABS is more prone to warping than
PLA. Good printing results will require a heatbed for
ABS. For PLA you can probably get printed parts
without warping without a heatbed.
There are many different kinds of ABS and PLA.
If your printer is perfectly tuned for the plastic of one
vendor you might need to redo your configuration after
you’ve switched vendors. PLA has a lower melting
temperature than ABS. Take into account however that
the thermistor on a NiChrome wire hotend typically
reports lower than actual temperatures. A thermistor
on a heatblock typically reports higher than actual
temperatures.
Your hotend temperature, extruder speed and axes
speeds all need to be in harmony for good printing
results. First try to get good printing results at a lower
extruder speed (100mm per second). Afterwards you
can try to increase the speed. As a rule of thumb
printing quality at higher speeds will be worse than at
lower speeds although the degradation is usually
acceptable.
1. Mechanical build
1.1. Wrenches and keys
1.2. Digital caliper
1.3. Spirit level
1.4. Plumb line
1.5. Installation of Z-axis bushings
1.6. Flat on motor shafts
2. Electronics build
2.1. Soldering
2.2. Cable stripper
2.3. DIY Sanguinololu build
You don’t need to be an electronics buff or mechanical
engineer in order to build your own 3D printer. If you
can screw a nut on a bolt you can build this printer.
You also don’t need to invest large amounts of
money in either parts or tools. The RepRap has been
designed around commonly available parts and using
commonly available tools.
1. Mechanical build
For the mechanical build you will need these tools and
the associated skills.
You only really need a hair dryer. You may find that
inserting your brass bushings or LM8UU linear
bearings into the integrated bushing holders is pretty
difficult. If you warm the bushing holders with a hair
dryer before inserting the bushings or bearings you
will find it becomes easier. The heat makes the plastic
more malleable.
2. Electronics build
Tools for the electronics build are required to solder
the components on the PCB (if you've bought a DIY
kit) and for endstops and motors.
2.1. Soldering
You need these basic soldering tools for building your
own electronics board. If you've bought a pre-
assembled board you probably still have to solder
cables:
Soldering iron with sharp tip. If you have a broad tip
you should consider changing it for a finer one.
Solder wire.
Third hand
[
12] A branch is like a separate track in a software
repository. In a branch things can be worked on in
parallel without affecting things in other branches.
RepRap software
3. Firmware
There are a few popular firmwares available for
RepRap 3D printers[13]. They are:
Sprinter: modern firmware with support for SD
cards and easy configuration
Teacup: claimed to be faster than Sprinter, more
elaborate configuration options
Teacup is a decent alternative for Sprinter. However,
because of its easier configuration we advise you to get
started with Sprinter.
git clone
https://github.com/kliment/Sprinter.
git
4. Skein software
Skeinforge is the most popular skein application in the
RepRap community but it’s also notoriously
complicated. Recently software developers in the
RepRap community have release Pronterface. This
application hides much of the complexity of
Skeinforge and is also host software for a RepRap
printer. When you install Pronterface there is no need
to install Skeinforge separately.
5. Host software
Pronterface is the easiest to use host software for a
RepRap 3D printer. It combines Skeinforge into a
much easier to use package. With Pronterface you can
load a STL file, have it converted to G-code and
control your RepRap Prusa Mendel 3D printer.
git clone
https://github.com/kliment/Printrun.
git
git clone
https://github.com/ahmetcemturan/SFA
CT.git skeinforge
[
13] See also the list of all available firmwares for
RepRap printers.
Buyer's guide
1. Printed parts
2. Vitamins
2.1. Electronics
2.2. Power supply
2.3. Stepper motors
2.4. Hardware kits
2.5. Extruder
2.6. Hotends
2.7. Kapton tape
Once you’ve decided to commit yourself you’ll have
to shop for parts. A RepRap printer consists of two
kinds of parts:
Printed parts for a RepRap Prusa Mendel
Vitamins or non-printed parts like nuts and bolts and
electronics.
Check out the RepRap Prusa Mendel bill of
materials (BOM) to get a feel of all the parts that are
required.
Warning about placing your orders
Don't order anything before checking your planned purchases on
the #reprap IRC channel. Only place your orders after the RepRap
community members on the IRC channel have approved.
1. Printed parts
In Europe printed parts can be sourced from nophead
or arthx. Nophead sells his parts on ebay. Arthx can be
contacted on the #reprap IRC channel (his handle is
arthx.) Nophead is based in the UK, Arthx in Poland.
For the US also check out LulzBot.com (based in
Loveland, Colorado, USA). For both US and Europe
also check eMAKERshop.com, a website where
RepRap community members buy and sell RepRap
parts.
You might also want to check out the casted parts
offerd by 2printbeta.de. These are reportedly the only
decent casted parts available.
2. Vitamins
2.1. Electronics
2.1.1. RAMPS
2.1.2. Sanguinololu
2.1.3. StepStick
2.5. Extruder
The printed parts for the Wade’s geared extruder are
usually part of the printed parts kit but be sure to
double-check. You will probably has to buy a separate
Wade's geared extruder hardware kit. These vendors
sell them:
2printbeta.de (based in Germany)
xyzprinters.com (based in the Netherlands)
2.6. Hotends
TODO
2.7. Kapton tape
Kapton tape is a space-age product. It's tape that can
resist the high temperatures typically found around a
RepRap 3D Printer. Kapton tape must be put on a
heated bed (the filament won't stick to the heated bed
itself) and optionally also on the hotend. You will need
two widths of kapton tape: 1cm and 5cm. A roll of
kapton tape typically holds about 33m. Check the
vendors mentioned above for kapton tape, also check
ruben-ikmaak (info [at] ikmaak [dot] nl, based
in the Netherlands.)
[
14] See the RepRap wiki page on stepper motors for
more details.
Build instructions
[
15] Here is one design for a suitable fan mount.
1. How to contribute
1.1. Overview
1.2. Create your free GitHub account
1.3. Fork the repository
1.4. Clone your copy of the repository
1.5. Making changes
1.6. Commit your changes
1.7. Push your changes
1.8. Create a pull request
2. Similar efforts
3. Contributors
This book is licensed under the Creative Commons
Attribution-ShareAlike 3.0 Unported License. Sharing
of this work is encouraged.
1. How to contribute
In case you want to fix typos - there's bound to be
plenty, edit this book or if you just want to add content
to this book you can do so onGitHub. You need to
have a GitHub account. Creating one is easy. You will
also need to install Git on your computer. There
are Git installation packages available for many
platforms. Once you have taken care of all that you
should log in to GitHub and fork the repository of this
book. Afterwards you can commit and push your
changes to GitHub. When that is done you can send
me a pull request. The next sections will discuss these
steps in more details. There's also a page on
GitHub dedicated to pull requests (the page however
might be too elaborate.)
1.1. Overview
The idea is simple enough: you want to make a small
or bigger change to the content of this book. Problem:
you don't have write access to the repository that holds
this book's source code. You could send me an e-mail
saying you would like to add this and that to such and
such section. That's tedious.
Actually you do have write access to this book's
source code, in a way. This book's source code is
hosted on GitHub, a site for collaborative sofware
development. On GitHub - once you have an account -
it is very easy to fork a repository. Once you've done
that you can make any changes you like.
Forking is software development jargon for
making a copy of a repository. Once the copy is made
this copy starts to live a life on its own but it still holds
a reference to where is came from: the original
repository. You can make changes on your copy of the
repository - making these changes is called a commit -
and you can then bring these changes to my attention.
Alerting me of your changes is called a pull request.
I wil have a look at your changes. I might copy
them entirely in the book. I might also make a few
changes first. Or I might feel lazy and ask you to make
some more changes before accepting your work into
the book. In any case, when your changes make it to
the book you will be listed as a contributor. The
following sections explain in more detail each step of
this process.
git@github.com:username/BuildingYour
Own3DPrinter.git
git clone
<replace_with_repository_URL>
gradlew publish
./gradlew
publish
git push
git pull
2. Similar efforts
There is a comparable effort to this one. It's called The
Incomplete RepRap Beginner's Guide and it is
maintained by COS.
3. Contributors
These people have kindly contributed to this book:
Kliment, spacexula, Mikko Kosonen, Nudel.