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RCJOSEB PVCore Manual

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THE PVCore 3D PRINTER
12/28/2016
BY RCJOSEB
PAGE 1 OF 107

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Summary of Contents for RCJOSEB PVCore

  • Page 1 THE PVCore 3D PRINTER 12/28/2016 BY RCJOSEB PAGE 1 OF 107...
  • Page 2 INTRODUCTION: This guide covers only the physical assembly of the PVCore 3D printer. It does not cover firmware setup, etc. A few months ago, I attended a STEAM (science, technology, engineering, arts and math) fair where a makers group was displaying two commercial grade 3D printers, a PolyPrinter and a Makerbot Replicator.
  • Page 3 So let’s be nice here and just link the guides back to my blog.  The guide is for personal use only by the end user to assist in building the PVCore.  The guide cannot be posted on any site other than my blog.

  • Page 4: Tools Needed

    THE PVCore 3D PRINTER TOOLS NEEDED: This is not a complete list of tools that are needed but it’s a great start:  Hand/power tool to cut the PVC pipe to length.  JB Weld ClearWeld or other similar epoxy.

  • Page 5: Printed Parts

    THE PVCore 3D PRINTER 3D PRINTED PARTS: The 3D printed parts are referenced throughout this build guide using letter codes. 12/28/2016 BY RCJOSEB PAGE 5 OF 107...
  • Page 6 THE PVCore 3D PRINTER 3D PRINTED PARTS: The 3D printed parts are referenced throughout this build guide using letter codes. 12/28/2016 BY RCJOSEB PAGE 6 OF 107...
  • Page 7 THE PVCore 3D PRINTER 3D PRINTED PARTS: The 3D printed parts are referenced throughout this build guide using letter codes. 12/28/2016 BY RCJOSEB PAGE 7 OF 107...
  • Page 8 THE PVCore 3D PRINTER 3D PRINTED PARTS: The 3D printed parts are referenced throughout this build guide using letter codes. 12/28/2016 BY RCJOSEB PAGE 8 OF 107...
  • Page 9 THE PVCore 3D PRINTER 3D PRINTED PARTS: The 3D printed parts are referenced throughout this build guide using letter codes. 12/28/2016 BY RCJOSEB PAGE 9 OF 107...
  • Page 10 THE PVCore 3D PRINTER 3D PRINTED PARTS: The 3D printed parts are referenced throughout this build guide using letter codes. 12/28/2016 BY RCJOSEB PAGE 10 OF 107...
  • Page 11 If you are going to paint the frame, do so only after it is assembled and the epoxy has completely cured. LINEAR BEARINGS: The PVCore can be assembled using either metal 6mm linear bearings (LM6UU-M) or 3D printed 6mm linear bearings (LM6UU- 3D). There are some pros and cons to each:...

  • Page 12: Frame - Parts

    THE PVCore 3D PRINTER FRAME - PARTS: The frame is assembled with the following parts:  02 x 14” PVC pipe for fronts (FF).  14 x 5.25” PVC pipe for verticals (FV).  10 x 6.625” PVC pipe for side horizontals (FSH).
  • Page 13 THE PVCore 3D PRINTER FRAME ASSEMBLY – LOWER BACK WALL:  Orient the PVC pipes and connectors as shown.  Slide the 3D printed parts (Z1) onto the bottom pipes (FBH) with the holes facing front to back.  Mix a small amount of epoxy, just enough to glue all of the pieces together.
  • Page 14 THE PVCore 3D PRINTER FRAME ASSEMBLY – UPPER BACK WALL:  Orient the PVC pipes and connectors as shown.  Mix a small amount of epoxy, just enough to glue all of the pieces together.  Apply a small amount of epoxy to the inside of each connector.
  • Page 15 THE PVCore 3D PRINTER FRAME ASSEMBLY – LOWER BEARING MOUNT HOLES: The rear bearing mounts (B1) are screwed into the frame at the upper rear elbows (FE). Once the frame is assembled, there is not enough space to drill the lower bearing mount holes, so it’s easier to do it now. Please note that you will not be drilling holes all the way through the pipe (FBH) and connector (FE) to the other side.
  • Page 16 THE PVCore 3D PRINTER FRAME ASSEMBLY – UPPER BEARING MOUNT HOLES: The red arrow points to a hole that will be drilled later when a vertical pipe (FV) is attached to the elbow (FE).  Orient the upper back wall as shown.
  • Page 17 THE PVCore 3D PRINTER FRAME ASSEMBLY – MIDDLE BACK WALL:  Orient the PVC pipes and connectors as shown.  Mix a small amount of epoxy, just enough to glue all of the pieces together.  Apply a small amount of epoxy to the inside of each connector.
  • Page 18 THE PVCore 3D PRINTER FRAME ASSEMBLY – COMPLETE BACK WALL:  Orient the assembled wall sections (lower, middle, upper) and pipes (FV) as shown.  Mix a small amount of epoxy, just enough to glue all of the pieces together.
  • Page 19 THE PVCore 3D PRINTER FRAME ASSEMBLY – REAR SIDE WALLS:  Orient the assembled wall sections (lower, middle, upper) and pipes (FSH) as shown.  Mix a small amount of epoxy, just enough to glue all of the pieces together.
  • Page 20 THE PVCore 3D PRINTER FRAME ASSEMBLY – LAST BEARING MOUNT HOLE:  Place a 3D printed bearing mount (B1) underneath the top right elbow (FE) as shown.  Use a 1/8” drill bit and the mount (B1) as a guide to drill the lower hole as shown by the red arrow.
  • Page 21 THE PVCore 3D PRINTER FRAME ASSEMBLY – MIDDLE SIDE WALLS:  Two middle side walls are required so it is easier to build them at the same time.  Orient the PVC pipes and connectors as shown.  Mix a small amount of epoxy, just enough to glue all of the pieces together.
  • Page 22 THE PVCore 3D PRINTER FRAME ASSEMBLY – MIDDLE SIDE WALLS:  Orient the middle side walls from the previous step onto the partially assembled frame as shown.  Mix a small amount of epoxy, just enough to glue all of the pieces together.

  • Page 23: Frame Assembly - Front

    THE PVCore 3D PRINTER FRAME ASSEMBLY – FRONT:  Orient the PVC pipes and connectors as shown.  Mix a small amount of epoxy, just enough to glue all of the pieces together.  Apply a small amount of epoxy to the inside of each connector.
  • Page 24 THE PVCore 3D PRINTER FRAME ASSEMBLY – FRONT MOTOR MOUNTS HOLES: The front motor mounts (M1) are screwed into the frame at the upper front elbows (FE). Once the frame is assembled, there is not enough space to drill the lower mounting holes, so it’s easier to do it now. Please note that you will not be drilling holes all the way through the pipes (FF) and (FSH) and connector (FE) to the other side.
  • Page 25 THE PVCore 3D PRINTER FRAME ASSEMBLY – FINAL: Please note that the frame is pictured upside down.  Orient the front assembly onto the partially completed frame as shown.  Mix a small amount of epoxy, just enough to glue all of the pieces together.
  • Page 26 THE PVCore 3D PRINTER FRAME ASSEMBLY – FINAL: This picture shows the completed frame as viewed from the front. 12/28/2016 BY RCJOSEB PAGE 26 OF 107...
  • Page 27 THE PVCore 3D PRINTER FRAME ASSEMBLY – FINAL: This picture shows the completed frame as viewed from the right. 12/28/2016 BY RCJOSEB PAGE 27 OF 107...
  • Page 28 THE PVCore 3D PRINTER FRAME ASSEMBLY – FINAL: This picture shows the completed frame as viewed from the left. 12/28/2016 BY RCJOSEB PAGE 28 OF 107...
  • Page 29 THE PVCore 3D PRINTER FRAME ASSEMBLY – FINAL: This picture shows the completed frame as viewed from the rear. 12/28/2016 BY RCJOSEB PAGE 29 OF 107...
  • Page 30 THE PVCore 3D PRINTER MOTOR MOUNTS - PARTS: The motor mounts are assembled with the following parts:  02 x 3D printed motor mounts (M1).  02 x Nema 17 motors (NM)  02 x 20 Tooth x 5mm bore motor pulleys (MP).
  • Page 31 THE PVCore 3D PRINTER MOTOR MOUNTS - ASSEMBLY:  Orient the Nema 17 motors (NM) so that their wires are facing you.  Orient the motor mounts (M1) as shown.  Attach the mounts (M1) to the motors (NM) using four M3 x 10mm screws (S10.0) and two washers (W6).
  • Page 32 THE PVCore 3D PRINTER MOTOR MOUNTS - ASSEMBLY: Orient a completed motor mount (M1) on top of the right, front elbow (FE) on the frame.  Drive the #6 x 2.0” screws (S2.0) and washers (W6) into the mount (M1) and frame as shown.
  • Page 33 THE PVCore 3D PRINTER BEARING MOUNTS - PARTS: The bearing mounts are assembled with the following parts:  02 x 3D printed bearing mounts (B1).  02 x 3D printed bearing supports (B2).  06 x 3D printed bearing spacers (B3).
  • Page 34 THE PVCore 3D PRINTER BEARING MOUNTS - ASSEMBLY: Please note that the 3D printed spacers (B3) have a slightly raised inner lip that is used to assist in preventing the 6mm radial bearings (608ZZ) from binding. The picture shows a completed bearing assembly: ...
  • Page 35 THE PVCore 3D PRINTER BEARING MOUNTS - ASSEMBLY: Attach the completed bearing assemblies to the bearing mounts:  Ensure that the bearing support (B3) is seated firmly into the recessed hole in the bearing mount (B1).  Place a 5/16 washer (W516) and 5/16 hex nut (N516) onto the 5/16 hex bolt (HB2.0).
  • Page 36 THE PVCore 3D PRINTER BEARING MOUNTS - ASSEMBLY: Orient a completed bearing mount (B1) on top of the right, rear elbow (FE) on the frame.  Drive the #6 x 2.0” screws (S2.0) and washers (W6) into the mount (B1) and frame as shown.
  • Page 37 THE PVCore 3D PRINTER Z AXIS SLIDE PARTS: The Z axis slide is assembled with the following parts:  01 x 3D printed Z axis slide (Z2).  02 x 0.25” x 12” threaded rods (T0.25).  02 x Metal LM6UU linear bearings )LM6UU-M) or 3D printed LM6UU linear bearings (LM6UU-3D).
  • Page 38 THE PVCore 3D PRINTER Z AXIS SLIDE ASSEMBLY: Please note that the following:  Attaching the two 0.25” x 12” threaded rods (T0.25) is OPTIONAL at this point as they will be removed later.  The hex nuts pictured to the left at the end of the threaded rod are threaded on without Blue Loctite.
  • Page 39 THE PVCore 3D PRINTER Z AXIS SLIDE ASSEMBLY: There is a process that I call “marrying” the linear bearings (LM6UU-M or LM6UU-3D) to the smooth rod (S6MM). The process involves taking each linear bearing one a time and finding out which rod it slides best on. This helps to minimize the amount of binds.
  • Page 40 THE PVCore 3D PRINTER Z AXIS SLIDE ASSEMBLY: The Z axis slide requires only one linear bearing (LM6UU-M or LM6UU-3D) on each side. If you are using the metal linear bearings (LM6UU-M) you can place two of them on each side as long as they are centered vertically within the Z axis slide hole.
  • Page 41 THE PVCore 3D PRINTER Z AXIS SLIDE ASSEMBLY:  Orient the completed Z axis slide as if you were facing the front of the PVCore.  Place the corresponding smooth rod (S6MM) next to its “married” linear bearing (LM6UU-M or LM6UU-3D) partner.
  • Page 42 THE PVCore 3D PRINTER Z AXIS MOTOR MOUNT - PARTS: The Z axis motor mount is assembled with the following parts:  01 x 3D printer motor base (M2).  01 x 3D printed motor plate (M3).  01 x Nema 17 motor (NM).
  • Page 43 THE PVCore 3D PRINTER Z AXIS MOTOR MOUNT - ASSEMBLY:  Orient the Nema 17 motor (NM) with the cables exiting to the right.  Slip the 3D printer motor mount (M2) over the motor (NM) with the cable cutout to the right.
  • Page 44 THE PVCore 3D PRINTER Z AXIS MOTOR MOUNT - ASSEMBLY: The purpose of these steps is to attach the motor mount (M2) to the PVC frame in a manner that will allow for adjustments to be made once the X and Y axis are completed. This helps to ensure the maximum print area.
  • Page 45 THE PVCore 3D PRINTER Z AXIS TOP BRACE – PARTS: The Z axis top brace is assembled with the following parts:  01 x 3D printed Z axis top rod support (Z3).  02 x 3D printed Z axis frame supports (Z4).
  • Page 46 THE PVCore 3D PRINTER Z AXIS FRAME SUPPORT – ASSEMBLY:  Place the PVC frame on its back and place a 3D printed Z axis frame support (Z4) on the center pipe (FV) as shown.  Center the holes in the Z axis frame support (Z4) with the T connector (FT).
  • Page 47 THE PVCore 3D PRINTER Z AXIS FRAME SUPPORT – ASSEMBLY:  Insert a #6 x 1.5” Phillips pan head screw (S1.5), #6 washer (W6) and #6 hex nut (N6) on the top hole.  Tighten down the #6 hex nut (N6) using Blue Loctite.

  • Page 48: Z Axis - Installation

    THE PVCore 3D PRINTER Z AXIS - INSTALLATION: During the installation of the Z axis, do not tighten the hex nuts (N516) up against the Z axis top support (Z4) so that the entire Z axis can be adjusted forwards and backwards. The placement of the Z axis will be determined when the X and Y axis components are installed.
  • Page 49 THE PVCore 3D PRINTER Y AXIS SLIDE PARTS: Please note that the picture does not show all of the quantities for each part. Actual quantities are listed below. After assembling the Y axis slide, I ran into issues with the 3D printed linear bearings (LM6UU-3D) binding and could not resolve the issue unless I re-designed the assembly.
  • Page 50 THE PVCore 3D PRINTER Y AXIS SLIDE BEARING MOUNTS ASSEMBLY: Assemble two sets of bearing mounts as done in previous steps except that these will use a 2.5” bolt instead of 2.0”. Please note that the 3D printed spacers (B3) have a slightly raised inner lip that is used to assist in preventing the 6mm radial bearings (608ZZ) from binding.
  • Page 51 THE PVCore 3D PRINTER Y AXIS SLIDE ASSEMBLY: The picture above shows a partially completed Y slide body. It will not be completed until after the X axis is completed. During the assembly process, the #6 x 2.0” Phillips head screws (S2.0) will be used to hold the Y slide body parts together while the bearing mount’s bolt (HB2.5) is inserted.
  • Page 52 THE PVCore 3D PRINTER X AXIS SLIDE PARTS: As with the Y axis slide, I ran into issues with the 3D printed linear bearings (LM6UU-3D) binding and could not resolve the issue unless I re-designed the assembly. I instead opted to use metal linear bearings (LM6UU-M), which worked much better.
  • Page 53 THE PVCore 3D PRINTER X AXIS SLIDE ASSEMBLY:  Insert the hotend (HE) into the hotend base (X3) with the wires exiting the hotend to the right.  Attach the hotend clamp (X4) to the hotend base (X3) using 1.0” screws (S1.0), #6 washers (W6) and #6 hex nuts (N6).
  • Page 54 THE PVCore 3D PRINTER X AXIS SLIDE ASSEMBLY:  Join the two X slide bodies (X2) together so the cutouts for the smooth rods (S6MM) face each other.  Hold the X slide halves (X2) using four 1.5” screws (S1.5), eight #6 washers (W6) and four hex nuts (N6).
  • Page 55 THE PVCore 3D PRINTER X AXIS SLIDE ASSEMBLY: The 2.0” screws (S2.0) will be used to hold the hotend in place while providing an anchor point to mount the GT2 belts. The hex nuts (N6) need to be 5/8” a way from the pan head of the screw. The distance can be measured manually with a ruler or by using something that is already 5/8”...
  • Page 56 THE PVCore 3D PRINTER X AXIS SLIDE ASSEMBLY: For this step, it is easier to remove the heat sink fan so just slide it off and re-install later. I had an issue with the linear bearings (LM6UU-3D) getting warped out of shape when tightening the 2.0” screws (S2.0) from the previous step.
  • Page 57 THE PVCore 3D PRINTER X AXIS ROD HOLDERS - PARTS: The Y axis rod holders are assembled with the following parts. Please note that the picture does not show all of the quantities for each part. Actual quantities are listed below: ...
  • Page 58 THE PVCore 3D PRINTER Y AXIS INSTALLATION: When installing the Y axis, keep the bearing mount on the side of the smooth rod (S5MM) that is farther away from the PVC frame. It may be necessary to cut the 6mm smooth rod (S6mm), depending on how well you cut the PVC frame. I had to shorten my smooth rods by about 0.25”.

  • Page 59: Axis Installation

    THE PVCore 3D PRINTER X AXIS INSTALLATION:  Place the completed X axis slide (X2) with its smooth rods (S6MM) onto the grooves of the Y slides (Y1/2).  Center each smooth rod (S6mm) so it’s evenly spaced between the Y slides (T1/2).
  • Page 60 THE PVCore 3D PRINTER Z AXIS INSTALLATION – POSITIONING:  Move the Z axis assembly back until the back of the motor mount assembly (M2) is 1.25” away from the PVC frame.  Place a small amount of Blue Loctite on the hex bolt (B516) on each side of the PVC pipe frame.
  • Page 61 THE PVCore 3D PRINTER GT2 MOTOR PULLEY AND BELTS – PARTS: To connect the X/Y axis to the motors, the following parts are needed:  02 x 5’ x 6mm GT2 belts (GT2-5).  02 x 5mm bore 20T Motor Pulleys (MP).
  • Page 62 THE PVCore 3D PRINTER GT2 MOTOR PULLEY AND BELTS – INSTALLATION: As with most CoreXY printers, the PVCore utilizes two belts for the X/Y axis motion, with one belt placed above the other one. The upper GT2 belt (GT2-5): ...
  • Page 63 THE PVCore 3D PRINTER GT2 MOTOR PULLEY AND BELTS – INSTALLATION: 12/28/2016 BY RCJOSEB PAGE 63 OF 107...
  • Page 64 THE PVCore 3D PRINTER GT2 MOTOR PULLEY AND BELTS – INSTALLATION: Here is a close up picture of the GT2 belts at the X Axis slide. 12/28/2016 BY RCJOSEB PAGE 64 OF 107...
  • Page 65 THE PVCore 3D PRINTER GT2 MOTOR PULLEY AND BELTS – INSTALLATION: Here is a close up pictures of the GT2 belts on the right side of the PVCore. 12/28/2016 BY RCJOSEB PAGE 65 OF 107...
  • Page 66 THE PVCore 3D PRINTER GT2 MOTOR PULLEY AND BELTS – INSTALLATION: Here is a close up picture of the GT2 belts on the left side of the PVCore. 12/28/2016 BY RCJOSEB PAGE 66 OF 107...
  • Page 67 THE PVCore 3D PRINTER Y AXIS ENDSTOP SWITCH MOUNT – PARTS: The Y Axis Endstop Switch is assembled with the following parts:  01 x PCB Endstop Switch (ESY1).  01 x 1/8” foam (ESY2).  01 x 3D printed Y Axis Endstop Switch Mount (ESY3).
  • Page 68 Place another 4” zip tie around all three parts to ensure a strong hold.  Use a 6” zip tie to hold the endstop cables to the PVCore.  Test the switch by moving the X Axis slide along the Y Axis.
  • Page 69 THE PVCore 3D PRINTER Y AXIS ENDSTOP SWITCH MOUNT – INSTALLATION: This picture shows where the X Axis slide engages the switch. 12/28/2016 BY RCJOSEB PAGE 69 OF 107...
  • Page 70 THE PVCore 3D PRINTER X AXIS ENDSTOP SWITCH MOUNT – BOM: The X Axis Endstop Switch is assembled with the following parts:  01 x PCB Endstop Switch (ESX1).  01 x 3D printed X Endstop Switch Trigger (ESX2). ...
  • Page 71 THE PVCore 3D PRINTER X AXIS ENDSTOP SWITCH MOUNT – ASSEMBLY:  Install the 3D printed X Endstop Switch Trigger (ESX2) by removing and using the existing screw (S1.5).  Remove the existing screws on the Y Axis Slide where the new screws (S1.25/S2.0) will go.
  • Page 72 THE PVCore 3D PRINTER PRINT BED - BOM: The print bed is a piece of window glass that you can purchase and have cut to size at your favorite hardware store. I had a piece of glass at home so I cut it to size myself. I placed some blue tape around the edges to prevent cuts.
  • Page 73 THE PVCore 3D PRINTER PRINT BED SUPPORTS – BOM: The Print Bed Support is assembled with the following parts:  2 x 3D printed bed support stiffeners (PB1).  1 x 3D printed front lower bed support (PB2).  2 x 3D printed rear lower bed supports (PB3).
  • Page 74 THE PVCore 3D PRINTER PRINT BED SUPPORTS – ASSEMBLY: Assemble the print bed supports off of the printer as shown in the picture above. Please note that the picture does not show all of the required hex nuts and washers. The arrows point to the location of where a hex nut (N0.25) and washer (W0.26) should be added.
  • Page 75 THE PVCore 3D PRINTER PRINT BED SUPPORTS – ASSEMBLY: The print bed support is mounted to the Z Axis slide by placing its threaded rod into the slide and locking it in place with opposing hex nuts. The upper print bed support is also locked in place using opposing hex nuts.
  • Page 76 THE PVCore 3D PRINTER PRINT BED SUPPORTS – ASSEMBLY: The 0.25” hex nuts (N0.25) labeled #1 and $2 are used to lock the 0.25” threaded rod (T0.25) against the print bed support. This helps in preventing the entire print bed support from flexing up and down. When tightening hex nut #2, do not overtighten it as it will then cause the print bed support to angle upwards.
  • Page 77 THE PVCore 3D PRINTER PRINT BED SUPPORTS – ASSEMBLY: This the view of the almost completed print bed support from the front. 12/28/2016 BY RCJOSEB PAGE 77 OF 107...
  • Page 78 THE PVCore 3D PRINTER PRINT BED SUPPORTS – ASSEMBLY: This the view of the almost completed print bed support from the top. 12/28/2016 BY RCJOSEB PAGE 78 OF 107...
  • Page 79 THE PVCore 3D PRINTER PRINT BED SUPPORTS – ASSEMBLY: This the view of the almost completed print bed support from the top 12/28/2016 BY RCJOSEB PAGE 79 OF 107...
  • Page 80 THE PVCore 3D PRINTER PRINT BED SUPPORTS – ASSEMBLY: Place the glass bed onto the upper print bed supports. 12/28/2016 BY RCJOSEB PAGE 80 OF 107...
  • Page 81 THE PVCore 3D PRINTER PRINT BED SUPPORTS – ASSEMBLY: As before, the 0.25” hex nuts, labeled #2, will be used as opposing nuts. Move the lower print bed support back and forth so that the upper print bed support is up against the glass bed.
  • Page 82 THE PVCore 3D PRINTER PRINT BED SUPPORTS – ASSEMBLY: Here is a picture showing the completed print bed. 12/28/2016 BY RCJOSEB PAGE 82 OF 107...
  • Page 83 THE PVCore 3D PRINTER Z AXIS END STOP SWITCH – BOM: The Z Axis Endstop Switch is assembled with the following parts:  1 X PCB Endstop Switch (ZES).  1 x 3D Print Endstop Switch Mount (ZM).  1 x Small piece of double sided tape (ZT(.
  • Page 84 THE PVCore 3D PRINTER Z AXIS END STOP SWITCH – ASSEMBLY:  Tighten the thumb screws on the print supports all the way down so the glass print bed is lowered. 12/28/2016 BY RCJOSEB PAGE 84 OF 107...
  • Page 85 THE PVCore 3D PRINTER Z AXIS END STOP SWITCH – ASSEMBLY:  Measure and cut the double sided tape (ZT) so it is the same width as the mount )ZM).  Remove one side of the backing on the double sided tape (ZT).
  • Page 86 THE PVCore 3D PRINTER Z AXIS END STOP SWITCH – ASSEMBLY:  Mount the endstop switch assembly onto the Z Axis top plate.  It should hold just by pressure butt if it feels loose then attach using double sided tape or glue.
  • Page 87 THE PVCore 3D PRINTER Z AXIS END STOP SWITCH – ASSEMBLY:  There should be a gap about 3mm – 5mm between the glass print bed and the print head nozzle.  This gap will be adjusted during the bed leveling procedure.
  • Page 88 THE PVCore 3D PRINTER RAMPS CASE - BOM: The RAMPS case is assembled with the following parts:  1 x 3D printed RAMPS case back (RCB).  1 x 3D printed RAMPS case front (RCF).  1 x 3D printed RAMPS case top (RCT).
  • Page 89 THE PVCore 3D PRINTER RAMPS CASE - ASSEMBLY: Attach the RAMPS case bottom (RCB) on the left side of the frame with the large cutout facing down:  Thread 4 x #6 Phillips head screws through the case bottom. ...
  • Page 90 THE PVCore 3D PRINTER RAMPS CASE - ASSEMBLY: Place strips of double sides tape onto the case bottom so that the strips cover the screw heads. 12/28/2016 BY RCJOSEB PAGE 90 OF 107...
  • Page 91 THE PVCore 3D PRINTER RAMPS CASE - ASSEMBLY: Place the RAMPS board into place and rotate the case and RAMPS so that they are horizontal. 12/28/2016 BY RCJOSEB PAGE 91 OF 107...
  • Page 92 THE PVCore 3D PRINTER RAMPS CASE - ASSEMBLY: It is better to connect the power cables now rather than after assembling the case:  Connect the Hot end wires.  Connect a JST connector for the filament fan.  Connect the power supply cables and an on/off switch if using one.
  • Page 93 THE PVCore 3D PRINTER RAMPS CASE - ASSEMBLY: Place the case front cover into position and tidy up the cables. To keep the cover in place, place a bead of hot glue along the edge where it meets the bottom of the case. Glue the remaining case parts in place except for the cover.
  • Page 94 THE PVCore 3D PRINTER RAMPS CASE - ASSEMBLY: Here is the completed case in its proper position. The case fan will be installed later. 12/28/2016 BY RCJOSEB PAGE 94 OF 107...
  • Page 95 THE PVCore 3D PRINTER RAMPS CASE - ASSEMBLY: This is a top view of the case. The larger cutout is for all of the cables except for the LCD display cables which are passed through the smaller cutout. 12/28/2016 BY RCJOSEB...
  • Page 96 THE PVCore 3D PRINTER FILAMENT FAN – BOM: The filament fan is assembled with the following parts:  1 x 40mm fan (FFAN40).  1 x Fan mount (FFM).  8 x 4” zip ties (SZT). 12/28/2016 BY RCJOSEB PAGE 96 OF 107...
  • Page 97 THE PVCore 3D PRINTER FILAMENT FAN – ASSEMBLY:  Use a 1/8 drill bit to clean out the four fan mounting holes. Do not drill all the way through the mount.  Insert a 4” zip tie through each hole from underneath.
  • Page 98 THE PVCore 3D PRINTER FILAMENT FAN – ASSEMBLY:  Place the fan onto the mount with a zip tie through each mounting hole.  Place another zip tie onto the existing one and tighten down the zip tie heads against each other.
  • Page 99 THE PVCore 3D PRINTER FILAMENT FAN – ASSEMBLY:  Loosen and remove the two existing screws from the X carriage.  Place the fan mount into position.  Re-insert the screws.  Thread and tighten down the nuts.  Zip tie any loose cables.
  • Page 100 THE PVCore 3D PRINTER EXTRUDER MOTOR MOUNT – BOM: For my extruder, I chose this one. The screw tabs can be used to connect it to the PVC pipes but I chose to remove them and support the extruder motor with a mount that supports the entire motor. The Thingiverse article lists the hardware needed to assemble the extruder.
  • Page 101 THE PVCore 3D PRINTER EXTRUDER MOTOR MOUNT – ASSEMBLY  Use the drill template to drill 1/8” or larger diameter holes where shown.  Dry fit the screws to ensure they fit. 12/28/2016 BY RCJOSEB PAGE 101 OF 107...
  • Page 102 THE PVCore 3D PRINTER EXTRUDER MOTOR MOUNT – ASSEMBLY  Drop the extruder motor in place. 12/28/2016 BY RCJOSEB PAGE 102 OF 107...
  • Page 103 THE PVCore 3D PRINTER EXTRUDER MOTOR MOUNT– ASSEMBLY  Connect the Pneumatic fitting to the extruder.  Connect the Bowden tube from the extruder to the hot end. 12/28/2016 BY RCJOSEB PAGE 103 OF 107...
  • Page 104 THE PVCore 3D PRINTER LCD CASE – BOM: The LCD case is assembled with the following parts.  Modified LCD case bottom.  LCD case front.  LCD Case button.  2 x #6-32 x 1.25” Pan Head Screws. ...
  • Page 105 THE PVCore 3D PRINTER LCD CASE – ASSEMBLY:  Attach the modified LCD case bottom to the front left side of the PVC core using the screws as before.  Install the LCD screen and button.  Hold the case together using zip ties or screws.
  • Page 106 THE PVCore 3D PRINTER CABLE CONNECTIONS AND CABLE ROUTING: I am not going to explain how to wire up the printer in this guide because electronics vary so follow the manufacturer’s instructions. I suggest using zip ties to route the cables neatly throughout the PVC frame.
  • Page 107 THE PVCore 3D PRINTER THE END 12/28/2016 BY RCJOSEB PAGE 107 OF 107...