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RepRap Prusa i3 Build Manual

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Prusa i3 - Build Manual

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Forward............................................................................................................................................................................... 4
1. Y-AXIS Frame............................................................................................................................................................... 5
1.1 Y-AXIS Long Sections.................................................................................................................................................................5
1.2 Y-Axis Rear Section (Motor)........................................................................................................................................................6
1.3 Y-Axis Front Section (Idler).........................................................................................................................................................8
1.4 Y-Axis Lower Frame Completed..................................................................................................................................................9
2. Z-AXIS Frame.............................................................................................................................................................10
2.1 Z-Axis Frame Mounting.............................................................................................................................................................10
2.2 Z-Axis Top/Bottom mounts (PLA)............................................................................................................................................12
2.3 Z-Axis Motors & End-stop.........................................................................................................................................................13
3. Build Plate & Heated Bed...........................................................................................................................................14
3.1 Build Plate Mounting..................................................................................................................................................................14
3.2 Y-axis belt...................................................................................................................................................................................15
3.3 Heated Bed Mounting.................................................................................................................................................................17
4. Ramps Mounting.........................................................................................................................................................18
4.1 Ramps mount..............................................................................................................................................................................18
4.2 Ramps Y & Z Wiring..................................................................................................................................................................20
5. X-AXIS + Z-AXIS Rods.............................................................................................................................................23
5.1 X-Axis Assembly........................................................................................................................................................................23
5.2 X-Axis Mounting........................................................................................................................................................................27
6. Extruder & Hot-End...................................................................................................................................................32
6.1 Hot-end Mounting .....................................................................................................................................................................32
7. X & Z-Endstop Triggers.............................................................................................................................................38
7.1 X-Endstop Trigger......................................................................................................................................................................38
7.2 Z-Endstop Trigger.......................................................................................................................................................................39
8. Final RAMPS Wiring..................................................................................................................................................40
8.1 Heated Bed Connecting..............................................................................................................................................................41
8.2 Build Plate Fans Connecting......................................................................................................................................................41
8.3 Hot-End Connecting...................................................................................................................................................................41
8.4 Power Supply / Hot-End Fan and RAMPS Fan Connecting.....................................................................................................42
9. Spool Mount................................................................................................................................................................ 44
9.1 Spool Mount Assembly..............................................................................................................................................................44
10. LCD / LCD Case & Mount........................................................................................................................................45
10.1 LCD Case Assembly.................................................................................................................................................................45
10.2 LCD Wiring .............................................................................................................................................................................46
11. First Power-on and Test.............................................................................................................................................47
11.1 First Power-on...........................................................................................................................................................................48
11.2 Motor Tuning (For reference, should not be required).............................................................................................................49
11.3 Filament Feeding......................................................................................................................................................................50
11.4 Extruder Calibration (Optional)................................................................................................................................................52
11.5 End-stop Test.............................................................................................................................................................................52
11.6 Bed Levelling Preparation........................................................................................................................................................53
11.7 Bed Levelling............................................................................................................................................................................54
11.8 First Print..................................................................................................................................................................................55
Appendix A - Motor Wiring.............................................................................................................................................57
Appendix B - Idler Pulleys...............................................................................................................................................63
Appendix C - Power Supply Wiring................................................................................................................................66
Appendix D - Firmware Update .....................................................................................................................................68
Appendix Z - Troubleshooting.........................................................................................................................................69
Version: 1.3
Page: 1

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  • Page 1: Table Of Contents

    Prusa i3 – Build Manual Table of Contents Forward....................................4 1. Y-AXIS Frame................................5 1.1 Y-AXIS Long Sections.................................5 1.2 Y-Axis Rear Section (Motor)................................6 1.3 Y-Axis Front Section (Idler).................................8 1.4 Y-Axis Lower Frame Completed..............................9 2. Z-AXIS Frame................................10 2.1 Z-Axis Frame Mounting................................10 2.2 Z-Axis Top/Bottom mounts (PLA)............................12...
  • Page 2 Prusa i3 – Build Manual Kit Parts : Version: 1.3 Page: 2...
  • Page 3 Prusa i3 – Build Manual Version: 1.3 Page: 3...

  • Page 4: Forward

    This manual is intended as a guide to your REPRAP Prusa I3 build, it would be impossible to cover everything involved in building and tuning a REPRAP Prusa I3 in a single 80 page guide, but it will greatly smooth the way to getting you up and running quickly.

  • Page 5: Y-Axis Frame

    Prusa i3 – Build Manual 1. Y-AXIS Frame 1.1 Y-AXIS Long Sections First take the two 350mm M8 smooth rods and slot one LM8UU bearing onto one, and two LM8UU bearings onto the other. Next slot the four Y-Corners onto the ends of the 380mm M10 Threaded Rods, then slot the two 350mm M8 Smooth Rods (with bearings) into the Y-Corner top slots, finally screw on and loosely hand tighten the M10 nuts (and washers).

  • Page 6: Y-Axis Rear Section (Motor)

    Prusa i3 – Build Manual 1.2 Y-Axis Rear Section (Motor) Fig 1.2 Parts: Firstly wire up a round shaft motor with about a 10cm extension length of wire & dupont connector. (see appendix A, motor wiring). Next slot the GT2 timing pulley onto the motor shaft with the teeth close to the motor and gently tighten the grub screws (see Fig 1.2a).
  • Page 7 Prusa i3 – Build Manual Next mount the motor assembly onto the two M8 threaded rods with the GT2 timing pulley teeth in the centre and the motor wires feeding out through the back of the two rods (Fig 1.2b). Just hand tighten the M8 nuts at this stage.

  • Page 8: Y-Axis Front Section (Idler)

    Prusa i3 – Build Manual 1.3 Y-Axis Front Section (Idler) Secure the idler onto one of the M8 threaded rods, dead center (loosely hand tighten) see Fig 1.3a If the idler pulley isn't pre assembled see appendix B (idler pulleys).

  • Page 9: Y-Axis Lower Frame Completed

    Prusa i3 – Build Manual 1.4 Y-Axis Lower Frame Completed To complete the lower frame slot the completed end sections into the Y-corners of the completed long side sections. Leave about 1 or 2 mm of M8 thread protruding and just loosely hand tighten the M8 nuts for now, they will be adjusted later when the build plate is mounted (section 3).

  • Page 10: Z-Axis Frame

    Prusa i3 – Build Manual 2. Z-AXIS Frame Fig 2.0 parts: 2.1 Z-Axis Frame Mounting Secure the frame between the two large 30mm M10 washers, then hand tighten on each side leaving approx 10cm between the flat rear of the Y-Corner and the rear of the frame (Fig 2.1a).
  • Page 11 Prusa i3 – Build Manual Once the lower frame in securely seated (press down) in the M10 notches of the Aluminium frame, and the measurement (about 10cm) is the same on each side and the 4 M10 bolts are hand tightened then flip the frame onto its side and firmly tighten using two M10 spanners (or adjustable spanners), Fig 2.1c.

  • Page 12: Z-Axis Top/Bottom Mounts (Pla)

    Prusa i3 – Build Manual 2.2 Z-Axis Top/Bottom mounts (PLA) Next bolt the Z-Top/Bottom PLA parts to the frame using 3 x M3 bolts/nuts/washers (Z-bottom Fig 2.2a) and 2 x M3 bolts/nuts/washers (z-top Fig 2.2b). M6 Rod holders (holes) on the outer edge, tighten M3 bolts/nuts firmly but not too firm, these parts tend to stay secure and its best not to stress the PLA by over tightening.

  • Page 13: Z-Axis Motors & End-Stop

    Prusa i3 – Build Manual 2.3 Z-Axis Motors & End-stop Mount the two motors with wires facing the back, the right side motor needs a 45cm extension and the left side motor no extension (just the dupont 4 pin connector) .. see appendix A Motor Wiring. While mounting the left side motor include the end-stop mount using the M3 bolts &...

  • Page 14: Build Plate & Heated Bed

    Prusa i3 – Build Manual 3. Build Plate & Heated Bed 3.1 Build Plate Mounting Firstly attach the Y-beltholder to the underneath of the waterjetcut Aluminium build plate, open side facing towards the two bearing slots (Fig 3.1a). Fig 3.1a: Next mount the build plate onto the 3 bearings of the Y axis smooth rods, using cable ties secured as tightly as possible –...

  • Page 15: Y-Axis Belt

    Prusa i3 – Build Manual Now is the time to tighten up all the nuts on the Y-axis, while ensuring the build plate slides freely on the smooth rods and is aligned straight, adjusting the nut positions slightly if necessary. Also make sure the motor end-stop isn't slanting forwards or backwards but sitting up straight so that the build plate will make square contact with it.
  • Page 16 Prusa i3 – Build Manual Next tighten the belt by slacking/positioning/re-tightening the idler between the M8 nuts (Fig 3.2b). The belt should be tight enough to be nice and springy .. but not extremely tight as that can stress the motor.

  • Page 17: Heated Bed Mounting

    Prusa i3 – Build Manual 3.3 Heated Bed Mounting After all the nuts on the Y-axis are tightened, mount the Heated Bed onto the Aluminium Build Plate, using the 25mm M3 bolts & washers secured with the 4 M3 nylock nuts. We use a fixed mounted front on the heated bed as it greatly simplifies bed levelling as well as increasing stability and reliability, without compromising on accuracy.

  • Page 18: Ramps Mounting

    Prusa i3 – Build Manual 4. Ramps Mounting Now is a good time to mount the Ramps board while access to the frame is easy before the X-axis goes on. Unplug the power connector from the Ramps board (parts picture), it will be wired up later to the power supply &...
  • Page 19 Prusa i3 – Build Manual Next slide the Arduino/Ramps into to the Ramps mount from the top of the mount (Fig 4.1b), power connectors facing down. Now tighten the clamping bolt (Not too tight) Fig 4.1b: Version: 1.3 Page: 19...

  • Page 20: Ramps Y & Z Wiring

    Prusa i3 – Build Manual 4.2 Ramps Y & Z Wiring Now is a good time to deal with the wiring for the Y and Z axis. Firstly secure the wiring out of the way of the build plate by cable tieing onto the M10 and M8 threaded rods (Fig 4.2b). Then connect the Z-axis motors to the top right twin 4pin connectors and the Y-axis motor to the middle right 4pin connector (red wire up).
  • Page 21 Prusa i3 – Build Manual Fig 4.2b Version: 1.3 Page: 21...
  • Page 22 Prusa i3 – Build Manual Fig 4.2c: Version: 1.3 Page: 22...

  • Page 23: X-Axis + Z-Axis Rods

    Prusa i3 – Build Manual 5. X-AXIS + Z-AXIS Rods Now to complete all the axis assembly we need to build the X-Axis assembly and fit onto the Z-Axis rods. 5.1 X-Axis Assembly Firstly assemble the basic X-Axis, take the X-Axis Idler and slot in one of the cage nuts to its housing (easiest done by compressing the sides of the cage nut with a pair of needle nose plyers.
  • Page 24 Prusa i3 – Build Manual Fig 5.1a: Fig 5.1b Version: 1.3 Page: 24...
  • Page 25 Prusa i3 – Build Manual Next bolt in place the X-Axis motor with 3 M3 16mm bolts, motor wire pointing down, and slot in place the GT2 belt pulley so that the teeth line up with the belt slot running through the centre of the assembly, then tighten the grub screws, the teeth of the pulley will be 2-3mm from the motor housing, see Fig 5.1d...
  • Page 26 Prusa i3 – Build Manual Now for the X-Axis M8 375mm smooth rods, firstly place two LM8UU bearings on one of the rods and push into the top M8 hole of the X-Axis motor (motor on the left, idler on the right), secondly place another 2 LM8UU bearing onto the other M8 375mm smooth rod and push into the bottom hole of the X-Axis motor, then push the X-Axis idler onto the other end of the rods, see Fig 5.1e.

  • Page 27: X-Axis Mounting

    Prusa i3 – Build Manual 5.2 X-Axis Mounting Now to mount the X-Axis assembly onto the Z-Axis smooth rods, firstly secure the 2 flexible CNC M5 couplings to the Z Motor shafts, dont push them far onto the shaft, just enough so that the grub screws tighten onto the motor shaft firmly (the further you push this coupling onto the shaft the less flexibility you get in the coupling ..
  • Page 28 Prusa i3 – Build Manual Next slot the M8 smooth rods through the LM8UU bearings of the assembled X-Axis (Fig 5.2c), adjust the ends of the X-Axis on the rods to line up with the smooth rods, then push the smooth rods down into the M8 holes on the top of the Z-motor mounts.
  • Page 29 Prusa i3 – Build Manual Next screw the two M5 threaded rods through the M5 cage nuts .. they should thread through very smoothly, if not don't force it , check the alignment, clean and oil the threaded rod and try again. Also you can try screwing in the other end of the rod which may have a better start to the thread.
  • Page 30 Prusa i3 – Build Manual Now turn both motors by twisting both flexible connectors simultaneously clockwise until the x-axis is raised about 35/40 cm further away from the build plate. Next cable tie the X-Axis carriage/extruder mount onto the 4 LM8UU bearings (flat face of the mount front facing, belt toothed slot at the top with the teeth pointing upwards, also note the lower MK8 mounting tabs in Fig 5.2e ..
  • Page 31 Prusa i3 – Build Manual Next you can increase the belt tension by slotting the small belt tensioner onto the belt close to where the belt leaves the teeth of the x-carriage, you may want to wait until the belt has been run in a bit before adding this.

  • Page 32: Extruder & Hot-End

    Prusa i3 – Build Manual 6. Extruder & Hot-End Now to mount the extruder and hot-end onto the X-Axis 6.1 Hot-end Mounting Now you can mount the MK8 onto to the x-axis. First check that the heater block / throat are firmly tightened, and the tip of the nozzle approx 37mm distance from the base of the aluminium extruder housing.
  • Page 33 Prusa i3 – Build Manual Fig 6.1a: Version: 1.3 Page: 33...
  • Page 34 Prusa i3 – Build Manual Now bolt the left and right MK8 mounting brackets together using the M3 35mm bolts and M3 nuts (slotted into the nut-traps on the right had bracket). Then slot the MK8 into the bracket, fan to the left, motor to the right and hot-end power / thermistor wires running to the rear.
  • Page 35 Prusa i3 – Build Manual Next slot the rear plate into place, endstop screwmount facing left (fan side) See Fig 6.1 c. Fig 6.1c: Next attach the build plate fans to the two fan brackets, the fans should be focused just underneath the brass hot-end nozzle.
  • Page 36 Prusa i3 – Build Manual Finally mount the whole assembly onto the x-carriage using 4 * 25mm M4 bolts, 8 M4 washers & 4 M4 nuts. Feed the hot-end and buildplate fan wires underneath the x-carriage, Hot-end fan wires over the top of the x- carriage.
  • Page 37 Prusa i3 – Build Manual Fig 6.1f (rear) : Version: 1.3 Page: 37...

  • Page 38: Z-Endstop Triggers

    Prusa i3 – Build Manual 7. X & Z-Endstop Triggers Now to setup the X and Z endstop triggers. 7.1 X-Endstop Trigger Screw in the M4 25mm X-Endstop trigger bolt on the left side of the MK8 mounting backplate and check that it lines up with the X-endstop.

  • Page 39: Z-Endstop Trigger

    Prusa i3 – Build Manual 7.2 Z-Endstop Trigger Check the Z-endstop trigger to make sure there is at least 7 mm of trigger protruding and that its lined up with the Z- endstop. The is important so that you dont crash the print head on your first auto-home test. See Fig 7.2a Version: 1.3...

  • Page 40: Final Ramps Wiring

    Prusa i3 – Build Manual 8. Final RAMPS Wiring Now to complete the RAMPS wiring including the hot-end, heated bed, fans and power supply (if you have not yet got a power supply ready to connect see Appendix C). For your reference here is a RAMPS 1.4 wiring diagram taken from RAMPS wiki : Version: 1.3...

  • Page 41: Heated Bed Connecting

    Prusa i3 – Build Manual 8.1 Heated Bed Connecting Strip the ends of the heated bed positive and negative wires and connect to the D8 +/- on the RAMPS (at the bottom directly left of the power connector). Also connect the Heated Bed thermistor cable to the middle two thermistor pins on the vertical column of six pins to the left of the Z-Axis motor headers (it doesn't matter about +/- for thermistor pins).

  • Page 42: Power Supply / Hot-End Fan And Ramps Fan Connecting

    Prusa i3 – Build Manual 8.4 Power Supply / Hot-End Fan and RAMPS Fan Connecting Now connect the RAMPS fan +/- and one of the power supply +/- to one side of the small green RAMPS power plug (note the +/- orientation : negative to the right with the plug screws facing up), also mount the fan onto one of the RAMPS mount crossbars using 2x16mm M3 bolts + washers + nuts.
  • Page 43 Prusa i3 – Build Manual Version: 1.3 Page: 43...

  • Page 44: Spool Mount

    Prusa i3 – Build Manual 9. Spool Mount 9.1 Spool Mount Assembly The spool mount can be used to mount a 1Kg reel of filament directly above the hot-end , with the filament feeding over the top of the reel and giving a path of least resistance into the extruder. This arrangement minimises the drag on the extruder from the filament.

  • Page 45: Lcd / Lcd Case & Mount

    Prusa i3 – Build Manual 10. LCD / LCD Case & Mount 10.1 LCD Case Assembly Firstly slot the LCD top first into the case section, then bolt on (using the 4x M3 bolts). Next clip the mount onto the top left hand corner of the frame and tighten using the M3 bolt. The LCD case then just slots into the top of the clip (see Fig 9.1a in the spool mount section)

  • Page 46: Lcd Wiring

    Prusa i3 – Build Manual 10.2 LCD Wiring Plug in the two ribbon cables to the back of the LCD and into the adapter with the ribbon cables running straight down the the ramps (Fig 10.2b). The adapter plugs into the top header of the RAMPS.

  • Page 47: First Power-On And Test

    Prusa i3 – Build Manual 11. First Power-on and Test Before powering on the printer for the first time and testing, screw in the X-endstop trigger (M4 20mm bolt) to the side of the extruder (Fig 11.0a) and make sure the Z-endstop is aligned with the trigger and the trigger bolt is protruding 7-8mm (Fig 11.0b).

  • Page 48: First Power-On

    Prusa i3 – Build Manual 11.1 First Power-on With everything connected up and the end-stops checked, power-on the printer from the power supply. The LCD should light up after after 1-2 seconds and say Factory 3D Ready, with the temperatures of the hot-end and heated bed displayed (room temp).

  • Page 49: Motor Tuning (For Reference, Should Not Be Required)

    Prusa i3 – Build Manual 11.2 Motor Tuning (For reference, should not be required) Before shipping your RAMPS has been tested, which involves setting the stepper driver pots to default power for the motors we ship, it is advised that you dont alter these settings unless you need to after identifying a print issue requiring it.

  • Page 50: Filament Feeding

    Prusa i3 – Build Manual 11.3 Filament Feeding Mount the spool assembly directly above the extruder (with the extruder as centred as possible). Make sure the end 10cm or so of the filament is very straight so the it will feed easily down into the hot-end throat (Its can help also to cut the end of the filament at an approx 45 deg angle).
  • Page 51 Prusa i3 – Build Manual Press down on the quick release lever at the front of the MK8 to allow you to push the straight part of the filament down into the MK8 throat, this may take a few attempts until you get the hang of keeping the filament straight and judging how far to push it down (any distance into the throat is fine).

  • Page 52: Extruder Calibration (Optional)

    Prusa i3 – Build Manual 11.4 Extruder Calibration (Optional) This step is not really necessary because your extruder comes pre-calibrated for 1.75mm filament, however optionally you can also check your calibration by marking say 3cm on the filament above the idler (with a marker or a small piece of tape) and then feeding 30mm via the menu and checking if 3cm exactly is fed down to the idler.

  • Page 53: Bed Levelling Preparation

    Prusa i3 – Build Manual 11.6 Bed Levelling Preparation If you have carefully performed all the steps from 11.5 you can confidently now perform a full auto-home, test that now and allow the Z-end-stop to trigger this time. Note the distance from the hot-end nozzle to the aluminium surface, it should be at least 8 or 9mm enough to comfortably fit the mirrored surface through, see Fig 11.6a (Note pictured is a J-Head hot-end but same procedure with the MK8)

  • Page 54: Bed Levelling

    Prusa i3 – Build Manual 11.7 Bed Levelling With mirrored surface in place, first tighten up your two nylon spacers supporting the front of the heated bed (unless your using 4 springs). Then perform an auto-home. Check the distance of the nozzle from the mirrored surface, if its close use a normal piece of paper (the type you would use to print on) and slide it between the nozzle and the surface.

  • Page 55: First Print

    Prusa i3 – Build Manual 11.8 First Print Once your bed is levelled, apply a thin layer of PLA glue solution (50 PVA glue, 50% water mixed together well) to the mirrored surface with a small paintbrush. Don't worry if it looks uneven or too thick (as in Fig11.8a), once the bed heats up the solution will dry to a near invisible smooth surface (Fig 11.8b)
  • Page 56 Prusa i3 – Build Manual Fig 11.8c – First Print: Version: 1.3 Page: 56...

  • Page 57: Appendix A - Motor Wiring

    Prusa i3 – Build Manual Appendix A – Motor Wiring Needed: Multipurpose Crimp Tool & Ideally a dupont crimper .. but you can use other crimpers or even plyers. 4 x Female Dupont Pin Connectors (2.54mm Pitch) + 1x 4pin Female Dupont Housing 4 x 1.5mm Bootlace Ferrules...
  • Page 58 Prusa i3 – Build Manual Fig A1: Next press the wire join together and slide over the bootlace ferrule, then crimp the ferrule to seal the joint (Fig A2). Then slide over the heat shrink tubing and shrink it in place using a lighter or other heat source (Fig A3).
  • Page 59 Prusa i3 – Build Manual Fig A2: Fig A3: Version: 1.3 Page: 59...
  • Page 60 Prusa i3 – Build Manual Finally attach a female Dupont connector to the end of each wire (if you have never crimped Dupont connectors before there are some youtube videos which are easily searchable show exactly how). Strip about 1cm from the end of each wire and fold the bare wire in half so you have about 0.5 cm to push into the connector.
  • Page 61 Prusa i3 – Build Manual Next slot the crimped connector into the housing (Fig A6). Fig A6: Version: 1.3 Page: 61...
  • Page 62 Prusa i3 – Build Manual Then repeat for all 4 wires in the order red,blue,green,black: Version: 1.3 Page: 62...

  • Page 63: Appendix B - Idler Pulleys

    Prusa i3 – Build Manual Appendix B – Idler Pulleys Needed: M4 Allen Key (3mm) M4 30mm bolt + nut 4 x M4 9mm washers 2 x M4 14mm washers 624zz bearing PLA Y-axis idler or X-axis idler The idler pulley assembly is identical for both Y and X axis, for this example we are using the Y-axis idler : Fig B1 (parts) Version: 1.3...
  • Page 64 Prusa i3 – Build Manual First slot a 9mm M4 washer onto the M4 bolt and poke through the idler (Fig B2) : Next Slot a 14mm M4 washer onto the bolt on the inner side of the idler (Fig B3) : Fig B3: Version: 1.3...
  • Page 65 Prusa i3 – Build Manual Next slot a 9mm M4 washer onto the bolt then the 624zz bearing (Fig B4). Fig B4: followed by another 9mm washer and the last washer on the inner of the idler another 14mm washer, finished off with a 9mm washer and nut on the outside of the idler (Fig B5).

  • Page 66: Appendix C - Power Supply Wiring

    Prusa i3 – Build Manual Appendix C – Power Supply Wiring Needed: LED Strip Power Supply (Min 20A) with 240v (min 3A) Mains Lead approx 60cm of paired red/black 12V/21A cable (2x30cm) 7 x M4 Ring Terminals (14-16 AWG) Heat Shrink Tubing (optional) Your LED strip 110-120/220-240v power supply is easy to connect up, but make sure your mains lead is unplugged from any socket (even if the socket has an off switch!).
  • Page 67 Prusa i3 – Build Manual Fig C2 (LED strip wired photo) One thing that can sometimes be confusing is the strip label above the screw terminals is often not aligned exactly over 9 screw terminals (see photo), so bear this in mind and double check your wiring.

  • Page 68: Appendix D - Firmware Update

    The Reprap RAMPS board is driven by an Arduino (Or Clone) Mega 2560 R3. The Mega 2560 is loaded with a firmware called Marlin (Factory 3D modified, source code included). This firmware can be loaded onto the Mega 2560 from a desktop PC (not a laptop which lacks sufficient USB power) via the USB port.

  • Page 69: Appendix Z - Troubleshooting

    Prusa i3 – Build Manual Appendix Z – Troubleshooting Hot-end heating up too slowly or not reaching temp at all. The front fan flow onto the hot-end is hitting too much of the nozzle section, fit the fan spoiler onto the fan (if it isn't already).

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