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RepRap Mendel Max 1.5 Build Manual

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RepRap Mendel Max 1.5
Build Manual G3D v1.2
1

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Summary of Contents for RepRap Mendel Max 1.5

  • Page 1 RepRap Mendel Max 1.5 Build Manual G3D v1.2...
  • Page 2 WWW.GADGETS3D.COM WWW.GADGETS3D.EU...

  • Page 3: Table Of Contents

    TABLE OF CONTENT Plastic Parts Set 1 Top Frame Bottom Frame Y Axis Y Axis Drive Z Axis Extruder X Axis Heatbed Endstop Spool Holder Ramps Fan Splitter & Cooling Plate 12.09.2013 Table Of Content...

  • Page 4: Plastic Parts Set 1

    PLASTIC PARTS SET 1 2x Belts Closing 1x Endstop Alu 20x20 Holder 1x Endstop Holder - 8mm 1x Endstop Holder - 10mm 2x Lower Vertex Left Lower 2x Lower Vertex Left Upper 2x Lower Vertex Right Lower 2x Lower Vertex Right Upper 1x PSU Holder 4x Top Vertex 1x Wires Holder - Large...
  • Page 5 1x Y Motor Mount 1x Y Rod Holder 2x Z Lower Motor mount 1x Z Belt Holder - 10mm 2x Z Lower Motor Mount 2x Z Lower Motor Mount Support Left Support Right 1x Z Motor Holder Upper 1x Z Motor Holder Lower 4x Z Rod Clasp - 10mm 2x Z Top Vertex - 10mm Duct*...

  • Page 6: Top Frame

    TOP FRAME Take: • 1x 340mm aluminum profile, • 4x T-slot nut, • 4x M5x10 SHCS, • 5x M5 washer, • 1x M5x10 FHS, • 1x lower vertex upper printed part; Top Frame...
  • Page 7 Assemble the screws to printed part like on picture above; Now take the aluminum profile and screw it to printed part using last M5x10 SHC screw and M5 washer; When the first end of aluminum profile is done, take last M5x10 FHS and screw it to the second end of alu- minum profile;...
  • Page 8 It should look like this; Repeat this for another 3 aluminum profiles; Top Frame...
  • Page 9 Take: • 2x Z rod clasp 10mm printed part, • 2x Z top vertex 10mm printed part, • 12x M5x10 SHCS, • 4x M5x20 SHCS, • 16x M5 washer, • 12x T-slot nut, • 4x M5 nut; Top Frame...
  • Page 10 Assemble them like on picture above; Now take 2x 420mm aluminum profile and assembly it using printed part, remember to turn aluminum profile so you get holes in order (holes from inside should be on top of the profile); 1.10 Do the same thing with the other end of aluminum profile - it should look like on picture above;...
  • Page 11 1.12 Collect previously assembled parts and assemble then to top frame like on picture above; 1.13 Assembled parts should look like on picture above; Top Frame...
  • Page 12 1.14 If everything is assembled right, you should have holes used for later tightening; 1.15 Using setaquare or other tool, make the profiles be 90° angle - like on picture above; Top Frame...
  • Page 13 1.16 Prepare: • top vertex printed part, • 4x M5x10 SHCS, • 4x T-slot nut, • 4x M5 washer; Top Frame...
  • Page 14 1.17 Assemble it like on picture above, do the same thing with other 2 parts; 1.18 When you get the right angle (90°) use top vertex printed parts to tighten the frame; Top Frame...
  • Page 15 1.19 Assembled top frame should look like on picture above. Top Frame...

  • Page 16: Bottom Frame

    BOTTOM FRAME Prepare: • 4x 420mm aluminum profile, • 4x 300mm aluminum profile, • 4x lower vertex lower printed parts, • 28x M5x10 SHCS, • 28x M5 washer, • 20x T-slot nut; Bottom Frame...
  • Page 17 Screw down 5x M5x10 SHCS with T-slot nuts into printed part, last two SHCS will not need T-slot nut, screw them to the aluminum profile; Repeat this for other 300mm aluminum profiles; Bottom frame...
  • Page 18 Take 4x 420mm aluminum profiles and screw them into already assembled parts, remember to turn aluminum profile so the holes in it should be from left and right side of the frame (it’s needed for PSU); Assembled bottom frame should look like on picture above;...
  • Page 19 Take: • one of the bottom frame, • bottom 420mm aluminum profile • 2x M5x10 SHCS, • 2x M5 washer, • 2x T-slot nut, • 2x M4x10 FHS, you can do it before assembling bottom frame or later; Bottom frame...
  • Page 20 Take 2x M4x10 FHS and place them into aluminum profile (like you would use T-slot nut) also remember to turn aluminum profile in right position so you can screw FHS later through the holes; Place the PSU holder on one of the M4x10 FHS; Bottom Frame...
  • Page 21 Turn it on other side and place on PSU, through the hole you can screw it a little but remember that PSU should be moveable for now; Bottom frame...
  • Page 22 2.10 Screw the PSU to aluminum profile through the hole in it but still remember it should be moveable for now; 2.11 Move the aluminum profile in desired destination (hole 1 or hole 2) and tighten one of the screws; 2.12 Put the aluminum profile into bottom frame and screw it tight;...
  • Page 23 2.13 Using T-slot nut and M5x10 SHCS, screw the PSU holder into top alumi- num profile, try to shake a little with bottom frame and make sure that PSU is solid placed; Bottom frame...

  • Page 24: Axis

    Y AXIS Prepare: • 2x 415mm 8mm diameter smooth rod, • 4x M5x16 SHCS, • 4x M5 washer, • 4x M3x16 screw, • 4x M3 nut, • 2x Y rod holder printed part; Y Axis...
  • Page 25 Assemble Y rod holders like on picture above, don’t tight anything now; Y Axis...
  • Page 26 Prepare: • 12x M4x10 SHCS, • 8x M4x16 SHCS, • 20x M4 washer, • 2x belt closing printed part, • 3x LM8UU bearing with housing, • 1x heatbed mount, • pre-assebled Y axis rods; Y Axis...
  • Page 27 Insert smooth rods into LM8UU bearings like on pictu- re above; Y Axis...
  • Page 28 Attach heatbed mount to bearing housing flat surfce using 12x M4x10 SHCS and 12x M4 washer; Y Axis...
  • Page 29 Tighten heatbed mount to bearing housing; Turn elements upside down like on picture above and attach belt closing printed parts using last eight M4x20 SHCS and eight M4 washers, don’t tight printed parts to housing, later it will be needed to insert belt between housing and closing;...

  • Page 30: Y Axis Drive

    Y AXIS DRIVE Prepare: • M8x30 SHCS, • 3x M8 washer, • 1x M8 nut, • 2x T-slot nut, • 2x M5x10 SHCS, • 2x M5x12 SHCS, • 1x M5x20 SHCS, • 4x M5 washer, • 3x M5 nut, • GT2 timing belt, •...
  • Page 31 Assemble Y idler tensioner, in order insert M8x30 SHCS, M8 washer, 2x 608 bearing, M8 washer then insert M8 nut into tensioner socket and tight it, remember to not overtight it, bearings should rotate easily without friction; Now use M5x10 SHCS with washer and T-slot nuts for assemble the Y idler mount next insert M5 nuts into Y idler tensioner slots and use M5x12 SHCS to connect printed parts into one piece like on picture above, last M5x20 SHCS and M5 nut goes on the top of the tensioner, with this...
  • Page 32 Now attach earlier assembled part to bottom frame on its shorter side; Y Axis Drive...
  • Page 33 Prepare: • Y motor mount printed part, • 2x M3x10 SHCS, • 2x M5x10 SHCS, • 2x M3 washer, • 2x M5 washer, • 2x T-slot nut, • 1x GT2 pulley, • 2x M3x5 headless screw, • 1x Nema 17 stepper motor; Y Axis Drive...
  • Page 34 Insert GT2 pulley onto Nema 17 stepper motor shaft and tight it using M3x5 headless screws; Attach printed part onto Nema 17 stepper motor using M3x10 SHCS and M3 washers; Y Axis Drive...
  • Page 35 Use last T-slot nuts and M5x10 SHCS, this will con- nect the part with aluminum profile; Take previously assembled parts shown on the picture above; Y Axis Drive...
  • Page 36 4.10 Now attach the Y motor mount to bottom frame but make it still moveable; Y Axis Drive...
  • Page 37 4.11 Take earlier assembled part and attach it to the upper aluminum profile; Y Axis Drive...
  • Page 38 4.12 Turn whole part upside down to get an access to belt closing parts; Y Axis Drive...
  • Page 39 4.13 Try to calculate how much belt you need then screw belt closings so it won’t move; Y Axis Drive...
  • Page 40 4.14 Attach assembled top frame to bottom frame; 4.15 After attaching top frame to the bottom frame which is almost ready the heatbed mount should be calibrated like on picture above, from 2 sides it should stop in the center of top vertex;...
  • Page 41 4.16 Turn assembled frame upside down again, in the pictu- re belt is not calibrated yet because Y idler mount and Y motor mount are still moveable; Y Axis Drive...
  • Page 42 4.17 Right arrangement is when top belt covers the bottom one, then you can tighten the screws of Y ilder mo- unt and Y motor mount. This operation needs some time, make everything very carefully to recive better preci- sion later; Y Axis Drive...

  • Page 43: Axis

    Z AXIS Prepare: • 2x Z lower motor mount printed part 2x Z lower motor mount support left printed part 2x Z lower motor mount support right printed part • 2x 10 mm rod clasp printed part 16x M5x10 SHCS 8x M3x10 SHCS •...
  • Page 44 Insert 4 x M5 nuts into the lower motor mount; do the same with the second lower motor mount, as it is shown in the picture above. Z Axis...
  • Page 45 Loosen the screw rod clasp using two M5x10 SHCS screws with washers Z Axis...
  • Page 46 Screw motor mount supports to motor mount plastic part using M5x10 SHCS with washers - on both sides Z Axis...
  • Page 47 Attach stepper motor to previously assembled motor holder using four M3x10 SHCS. Do not tighten them now. Do it as it is shown in the picture above. Do the same to the second stepper motor. Z Axis...
  • Page 48 Prepare: • Z belt holder printed part • Z motor holder upper printed part • Z motor holder lower printed part • 1x M8x30 SHCS • 4x M4x20 SHCS • 26 x M3x20 SHCS • 3x M8 washer • 24x M3 washer •...
  • Page 49 Insert 4 x LM8UU bearings into Z belt holder printed part and use M3x20 screws with washers and nuts to lock the bearings. Z Axis...
  • Page 50 Insert M8 nut into the mounting hole. Se- cure M8 nut with two M3 x 20 SHCS screws, nuts and washers. Z Axis...
  • Page 51 Insert LM10UU bearings into Z belt holder printed part and again use M3x20 screws with washers and nuts to lock the bearings. Z Axis...
  • Page 52 5.10 Prepare: • M8x30 SHCS • 2x 608 bearing • 3x washer(fotka 0002) 5.10.1 Put the M8 washer on the screw, 2x 608 bearings and again 2 x M8 washer, it should looks like on the pictures below. Z Axis...
  • Page 53 5.11 Take Z Motor Lower printed part and insert M8 nut. Screw M8 bolt with bearings to this nut, as you can see in the picture below. Z Axis...
  • Page 54 5.12 Take the bottom part of Z motor mount and place one M8 nut inside it. Z Axis...
  • Page 55 5.13 Insert LM10UU bearings into Z motor holder upper printed part and again use M3x20 screws with washers and nuts to lock the bearings. Z Axis...
  • Page 56 5.14 Take the bottom part of Z motor mount and assembly it like in picture above using four M4x16 SHCS and nuts. Don’t tight up the bottom part yet. Z Axis...
  • Page 57 5.15 Prepare: • Previously assembled motor mounts • 1x Previously assembled Z motor holder - upper and lower one • 1x Previously assembled Z belt holder • 8x M5x10 SHCS screws • 8x T-slot nuts • 2x Aluminum coupler • 2x Threaded rod Z Axis...
  • Page 58 5.16 Attach Z axis couplers to motor shafts as you can see above. Put the coupler on the motor shaft on the smaller hole side. Screw them tightly. Z Axis...
  • Page 59 5.17 Put the threaded rod into the hole at the top of coupler as you can see in the picture above. Tight it up using headless screws. Do the same to the second stepper motor. Z Axis...
  • Page 60 5.18 Take the Z motor mount previously assembled and insert X motor mount into the threaded rod. Do it for the X belt holder like you did it previously. It should look like in the picture below. Z Axis...
  • Page 61 5.19 Insert 4 x T-slot nuts into horizontal profiles on the left side of the frame. Assembly previously mounted motor holder parts, set to the side of the frame using four 4x10 SHCS screws and nut inside the pro- files. It should look like in the picture above. Make sure that the motor holders are in the middle position of the frame.
  • Page 62 5.20 Prepare: • 2x Smooth rod 10mm • 4 x 5x 10 SHCS • 4 x M5 Washer • 2 x Rod clasp Z Axis...
  • Page 63 5.21 Attached the rod clasp to upper vertex using two 5x12 SHCS with washers. Do the same on the second side of the frame. Z Axis...

  • Page 64: Extruder

    EXTRUDER Prepare: • GT2 timing belt, • 8x M3x10 screw, • 2x M3x20 screw, • 2xM3x25 screw, • 4x M3x30 screw, • 2x M3x40 screw, • 1x M3x8 headless screw, • 18x M3 washer, • 13x M3 nut, • 2x M8 nut, •...
  • Page 65 Take X carriage printed part and assembly it with LM8UU bearings; Tighten bearings using the M3x20 screws and M3 nut; Extruder...
  • Page 66 Put hobbed bolt into 608 bearing, then assembly it with printed part like on picture above, remember to use M8 washers so bearing will work without bigger friction; Extruder...
  • Page 67 Put another 608 bearing, M8 washer and M8 nut to hobbed bolt (don’t tighten too much, hobbed bolt should move easily without friction); Extruder...
  • Page 68 Take bigger printed gear and M8 nut and assembly it like on picture above, this operation is tricky so re- member that 1st M8 nut should be a little loose so the hobbed bolt will move easily and 2nd M8 nut should tighten the printed wheelgear;...
  • Page 69 Take another extruder printed part and put M3 nut into the slot, and adjust it to already assembled part; Screw the M3x25 screw into extruder, dont make it too tight, printed part should move easily, assembled part should look like on picture above; Extruder...
  • Page 70 Take another 608 bearing and assembly it with extruder, it should make „click” sound, try to rotate the bearing to test if it fits; 6.10 Put M3 nuts into the top slots of extruder and assembly it with M3x40 screws; Extruder...
  • Page 71 6.11 Assembled part should look like on picture above (other solution - use springs for M3x40 screws to get filament tightener); Extruder...
  • Page 72 6.12 Take smaller wheelgear and put M3 nut into the slot then screw the headless screw into it, next step is to tighten wheelgear onto stepper motor shaft using the headless screw; Extruder...
  • Page 73 6.13 Take duct fan printed part and fan, screw the fan into printed part using the M3x10 screws; Extruder...
  • Page 74 6.14 Going back to assembled compo- nents, take X carriage and assembly it with G3D Hotend 1.2, holes in printed part should fit with the G3D hotend 1.2 holes; Extruder...
  • Page 75 6.15 Now put two M3 nuts into the slots of assembled extruder, using two M3x30 screws assembly these parts; Extruder...
  • Page 76 6.16 Take already assembled Nema 17 stepper motor and adjust it with extruder assembled part, using the M3x10 screws tighten the stepper motor; Extruder...
  • Page 77 6.17 Take previously assembled duct fan part and use M3x10 screws to tighten it to extruder. Extruder...

  • Page 78: Axis

    X AXIS Take 2x 445mm 8mm diameter smooth rod and insert it through the bearings; X Axis...
  • Page 79 Take assembled extruder part and push smooth rods through it, after leveling the other Z rod mount (make the same high both of Z rod mounts), smooth rod should go through X car- riage and Z motor holder - it’s the clo- sing of smooth rod and then it should be tightened so smooth rods won’t move or rotate;...
  • Page 80 Prepare: • Nema 17 stepper motor, • 4x M3x10 SHCS, • 4x M3 washer, • 1x GT2 pulley, • 2x M3x5 headless screws; X Axis...
  • Page 81 Mount the Nema 17 stepper motor onto Z rod mount like on picture above, then screw motor to Z mount using M3x10 screws and M3 washers; Now insert GT2 pulley and tighten the headless screws from two sides; X Axis...
  • Page 82 Now prepare GT2 timing belt, it’s ready to be mounted; X Axis...
  • Page 83 Prepare: • 2x M3x30 SHCS, • 2x M3 washer, • 3x M3 nut, • X carriage printed parts; X Axis...
  • Page 84 Place GT2 belt like on picture; Take one of X carriage printed part, insert M3x30 SHCS with washer into hole; X Axis...
  • Page 85 7.10 Now insert bottom GT2 belt (teeth facing upward) and tighten the screw using M3 nut (M3 nut should hide in a hole); 7.11 Now take last unattached fan, assemble it with screw and nut; X Axis...
  • Page 86 7.12 Take last X carriage parts and M3x30 SHCS with washer, tigthen the belt a little and assembly these parts (last M3 nut should hide in a hole); X Axis...
  • Page 87 7.13 Correct assembly should look like this, top part of belt should cover the bottom part from top view; X Axis...

  • Page 88: Heatbed

    HEATBED Prepare: • heatbed, • mirror plate, • 4x 3x20 spring, • 4x M3x30 SHCS, • 8x M3 washer, • 4x M3 nut, • 4x Clips; Heatbed...
  • Page 89 Take heatbed and in order insert M3x30 SHCS with wa- sher then insert the spring, aluminum plate*, washer and M3 nut, repeat this operation for another holes; Now attach heatbed onto aluminum plate, this is tricky operation so be patient (Remember: M3x30 SHCS, washer, heatbed, spring, aluminum plate, washer, M3 nut);...
  • Page 90 Now place the mirror plate onto heatbed; Adjust mirror plate with heatbed lines; Heatbed...

  • Page 91: Endstop

    ENDSTOP Prepare: • 3x endstop, • 6x M3x10mm SHCS, • 1x M5x10mm SHCS, • 1x T-slot nut, • 1x endstop holder 8mm, • 1x endstop holder 10mm, • 1x endstop alu printed part; Endstop...
  • Page 92 Now attach endstops to plastic parts using the M3x10mm screws; Take endstop holder 10mm printed part with endstop on it and slide it onto Z smooth rod (endstop should aim at Z holder printed part); Endstop...
  • Page 93 Take endstop holder 8mm printed part with endstop on it and slide it onto X smooth rod, endstop should be betweeen smooth rods (endstop should aim for X carriage); Last endstop should be placed in bottom frame, on top aluminum profile (endstop should aim for Y aluminum plate); Endstop...

  • Page 94: Spool Holder

    SPOOL HOLDER 10.1 Prepare: • 100mm aluminum profile, • aluminum extrusion holder, • 2x M5x10 SHCS, • 2x T-slot nut; Spool Holder...
  • Page 95 10.2 Take aluminum extrusion holder and assemble 2x M5x10 SHCS with T-nuts; 10.3 Now insert 100mm aluminum profile onto aluminum extrusion holder and tighten the screw; Spool Holder...
  • Page 96 10.4 Attach assembled part on top corner; Spool Holder...

  • Page 97: Ramps

    RAMPS 11.1 Unpack RAMPS box (RAMPS 1.4 + arduino + sd shield);...
  • Page 98 11.2 Take motor wires and solder the same colors from wires with connector and use tape to protect the connection, this will apply to X, Y and E motors; connector wires motor wires black yellow green blue blue green...
  • Page 99 11.3 Take thermistor wires with connector and thermistor (heatbed, hotend), solder it like before, and use tape to protect the connection; 11.4 After soldering motors, endstops, thermistors you can connect them into RAMPS board;...
  • Page 100 11.5 Take endstop connector and place it; 11.6 Thermistor connectors should go near endstop pins;...
  • Page 101 11.7 Take motor connector and connect it near drivers; 11.8 Take flat screwdriver to loose power connector then connect power wires;...
  • Page 102 11.9 With the same screwdriver loose hotend connector then connect wires, after this operation tighten the screws;...
  • Page 103 11.10 RAMPS 1.4 wiring schematic;...
  • Page 104 *ADDITIONAL RAMPS DISASSEMBLY 11.11 Use flat screwdriver to under- mine the A4988 step motor drivers,...
  • Page 105 11.12 Use the same tool to deatach arduino module from RAMPS, after this unplug power socket; 11.13 Now your RAMPS is fully disassembled.

  • Page 106: Fan Splitter & Cooling Plate

    FAN SPLITTER & COOLING PLATE 12.1 Collect parts needed for assembly; Fan Splitter & Cooling Plate...
  • Page 107 12.2 Plug-in fan splitter power wire into RAMPS socket (or any other source of 12V); Fan Splitter & Cooling Plate...
  • Page 108 12.3 Unpack fansplitter parts with plastic spacers, 4x M3x10 SHCS, 5x M3 plastic nut; Fan Splitter & Cooling Plate...
  • Page 109 12.4 Unscrew two screws from plastic frame; Fan Splitter & Cooling Plate...
  • Page 110 12.5 Take already disassembled part and 3x M3x10 SHCS, 3x Plastic spacer and assemble like on picture above; Fan Splitter & Cooling Plate...
  • Page 111 12.6 Now attach top part with fans on your already assembled part with spacers and connect them using two screws; Fan Splitter & Cooling Plate...
  • Page 112 12.7 Now take RAMPS with already connected fansplitter board and as- semble fans onto it. Use plastic M3 nuts to tighten part; Fan Splitter & Cooling Plate...
  • Page 113 12.8 Now connect fans into fan splitter sockets; 12.9 Fan splitter board is successfully connected. Fan Splitter & Cooling Plate...

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