Reprap Prusai3 Diy Assembly Guide

RepRap
Prusai3 Assembly Guide
Table of Contents
Introduction 0
Bill of Materials 1
Frame Assembly 2
Base Platform Assembly 3
Wiring Electronics 4
Configure Firmware 5
2
RepRap Prusai3 Assembly Guide
Overview
This book will teach you how to build a complete Do It Yourself 3D Printer and start 3D
printing your own designs.
RepRap Prusa i3 3D Printer Full DIY Kit in affordable price in India.
Prusa i3 is a proven RepRap 3DPrinter with tens of thousands users all around the world.
This kit is based on the Prusa i3, including all parts you need to build a 3D printer and make
your first prints.
Introduction 3
About aSensar
aSensar™ is a #design, #engineering and #manufacturing company in #TN, #India founded
in 2012
We are a small team who love #making, #innovating, and #creating inspiring products that
are a fun, open source, made in india and easy to use for everyone.
We work to #Make things simple, accessible and better for the humanity.
Introduction 4
About DIY-India.com
DIY-India.com is online shop to empower the Indian Makers, Students, and Startups with
quality products at low price with multiple options, fast and reliable delivery, and a trusted
and convenient experience. Thus enabling the Indian makers community to invent/discover
things that will change the world.
About RepRap
The word RepRap is short for Replicating Rapid-prototyper.
RepRap is a practical self-copying 3D printer introduced in the video on the left - a self-
replicating machine. This 3D printer builds the parts up in layers of plastic. This technology
already exists, but very expensive. RepRap is a community invents, makes and share
designs and documents under free license. That way it's accessible to communities in the
developing world as well as individuals in the developed world.
You can know more on http://reprap.org/wiki/About
About Prusa i3
Prusa i3 is a RepRap design by Josef Prusa and RepRap Core Developer. Prusa i3
(iteration 3) is the latest and the most widely built RepRap model.
Prusa i3 Project page: http://reprap.org/wiki/Prusa_i3
License
This book by aSensar is licensed under a Creative Commons Attribution-ShareAlike 4.0
International License.
Introduction 5
Bill Of Materials
As our first step, we will prepare the complete list of parts needed.
BOM (Bill Of Materials)

This kit includes everything you need to assemble complete RepRap Prusai3. Kits content
are below.
Bill of Materials 6
Product Quantity
Laser Cut Parts, [6mm Acrylic] 1

Injection Moulded Plastic Parts Set 1
SolidCube Extruder Set 1
All Metal Chilly Hotend Set 1

Chrome Plated Smooth Shaft Ø8 x 320mm 2
Threaded Rod M5 x 300mm (MS) 2

RAMPS 1.4 1
Mega 2560 1
StepStick Stepper Driver 4

Endstop with cables 3
MK2b PCB Heated Bed 1
Thermistor with 2Pin Wire 1
ATX 300W Power supply with cables 1
45 N-cm NEMA 17 Stepper Motor 2
28 N-cm NEMA 17 Stepper Motor 2
LM8UU Linear Bearing 10

625zz Bearing 4
GT2 Timing Belt 6mm x 65 cm 1

GT2 Timing Belt 6mm x 85 cm 1
GT2 Timing Pulley 6mm x 20 Tooth 2
5x5 Aluminium Rigid Shaft Coupling 2

Crimping Terminal 10
Spring L20,ID8,OD10 4
Spiral Slew 1 Meter 1
Fasteners: Screws, Bolts, Nuts, Washers 1 Pack
Bill of Materials 7
Assembling Prusa i3 Frame

To make it easier and simpler to assemble Prusai3 kits sold by DIY-India.com are
redesigned the frame to use only M3 Nuts and M3x20 Allen Hex bolt, so you need not to
worry about which bolt to use.
So for assembling the frame where ever we say nut/nuts use M3 nut, where every we
mention bolt/bolts use M3x20 bolt
Main frame and side frame assembling

As a first step, we should attach the main frame with side frame.
Frame Assembly 8
The main frame will have slots, where side frames will have compatible tenon, insert the
tenon into the solts as show in the below picture.
Fasten the Main frame with Side frame using M3 nuts and bolts as show in the pricture.
Top Plate Assembling

Now place the top frame as show and fastem them with the nuts and bolts.
Frame Assembly 9
Z-Motor Mount Assembling

As show in the below pictures use two small side plates and fasten them to the Main frame
using M3 nuts and bolts.
Frame Assembly 10
Now put the top plate as show in picture and fasten them with the small z mount side plate.
Frame Assembly 11
Install the motor

Mount the Z motor as shown in the picture use M3x? bolt and fasten them in four corner.
Frame Assembly 12
Completed
Once you have done all the above steps, you should see your frame assemlby completed
and should look similar to below picture.
We have compiled all the above steps in a video, you can watch it in Youtube:
https://www.youtube.com/embed/56igsZO_Cgw
Frame Assembly 13
Assembling Base/Bed Platform

To make it easier to assemble we modified the design of Prusa i3, and changed M8
threaded rods for all threaded rods and M8 nuts for all Nuts (same size), you only need to
make sure that you used correct length rods.
Checkout animation video on how to Assembe base platform on youtube:

https://www.youtube.com/embed/PcWuVSTgF7Q
X,Y and Z axis Assembling









Heatbed Mounting
Now you should have the printer assembled almost 50%, now lets put the Heatbed.

Follow the instruction in the video to prepare the heabed and mounting
https://www.youtube.com/embed/xVRny7qUN24
Note: If you don't get silicon glue, then use simple kapton tape, that should suffice, we have
included the small length of Kapton tape in the KIT.

Wiring Electronics
Prepare the RAMPS electronics
Install Jumpers
Short the PINS (Highlighted in Green) under Step Stick using Jumpers. Theses jumper
determines the stepping mode of the step stick. Default is 1/16 micro stepping all 3 jumpers
need to be installed under drivers for 1/16 micro stepping mode
Installing StepStick
Install heat sink on Step Stick
Assembling RAMPS and Arduino

Assembling RAMPS means simply stacking RAMPS1.4 shield on top of Mega 2560.
Note: Make sure to Match the PIN in Step Stick and RAMPS,
else the step stick will be damaged
Step Stick Assembly, note the direction of Trim Pots
Make sure your assembled electronics looks like the picture
RAMPS After Assembly
Wiring Components
Connecting Hotend, HeatBed
Connector Pairs D8, D9, D10 are used for connecting these devices. This configuration is
based on Firmware configuration (Marlin). Depending on your Marlin firmware configuration
you can wire the hardware
Configuration 1: Hotend (D10) + Fan (D9) + Heat Bed (D8) Configuration 2: Hotend (D10) +
Hotend (D9) + Heat Bed (D8)
Configuration 1: Hotend (D10) + Fan (D9) + Heat Bed (D8)

Fan is optional, you can leave it unconnected
Configuration 2: Hotend (D10) + Hotend (D9) + Heat Bed

(D8)
Some of India makers asked us how to connect two extruder setup
Connecting Thermistor, Limit switch and Power supply

Each is explained in separate sections below
Connecting End Stops

Each is explained in separate sections below
Wire the power supply

We have modified the power supply and pre crimped the wire, so you can just plug and play
without worries.
We have used the branded ATX power supply, which is used in computer CPU box. The
power supply has ratting of 450W-300W and can deliver up to 12V @ 15A which is sufficient
for driving the PCB Heatbed and all its electronics
Connecting Thermistor
In the Picture T0, T1, T2 are for thermistor: Hotend 1 (T0), Heat bed (T1), Hotend (T2)
Connection Diagram
After following all above steps, your wiring should look like below diagrams
Connection Diagram 1
Connection Diagram 2
Configure and Compile Marlin Firmware

So you have assembled your hardware and wired your electronics. Now you need to
program the firmware in to RAMPS electronics to bring it to life. In this how to make guide
we will see how to configure, compile and program Marlin firmware into RAMPS electronics.
Download Marling Firmware

Firmware is the software that will run inside the RAMPS elections, though there are many
firmwares like Repetier, Marlin, etc. We will use Marlin firmware for our Guide.
Download Marlin from https://github.com/MarlinFirmware/Marlin

Select the Download Zip button on the right side of the screen.
Unzip the Zip file
Configure Marlin Firmware for RAMPS and

Prusa i3
To get started with Customizing and Configuring Marlin for RepRap Prusa i3 3D Printer, use
these general configuration as a starting point and fine tune the setting until you get best
prints.
In the extracted source, open Marlin/Configuration.h file with editor
Set the baudrate
#define BAUDRATE 115200
Set the MOTHERBOARD define to RAMPS

This will configure the RAMP boards with 1xExtruder, 1xFan, 1xBed, see Marlin/boards.h file
for more configuration
#ifndef MOTHERBOARD
#define MOTHERBOARD BOARD_RAMPS_13_EFB
#endif
Set Name and UUID (Optional)

This is optional, uncomment and set below defines values
#define CUSTOM_MENDEL_NAME "Prusa i3"

#define MACHINE_UUID "12941deb-3b62-4c18-8d53-10fcd7338bf3"
Set no. of extruder's

This defines the number of extruders
#define EXTRUDERS 1
Set the thermistor
#define TEMP_SENSOR_0 11
#define TEMP_SENSOR_BED 11
Set MAX temperature limits

When temperature exceeds max temp, your heater will be switched off. This feature exists to
protect your hotend from overheating accidentally, but NOT from thermistor short/failure!.
You should use MINTEMP for thermistor short/failure protection.
#define HEATER_0_MAXTEMP 230

#define BED_MAXTEMP 150
Set PID values

Later you can recalculate the values by running PID tuning
#define DEFAULT_Kp 26.88

#define DEFAULT_Ki 1.57
#define DEFAULT_Kd 114.95
Endstops settings
Sets direction of endstops when homing; 1=MAX, -1=MIN
#define X_HOME_DIR -1
#define Y_HOME_DIR -1
#define Z_HOME_DIR -1
Set the direction of XYZ and E axis Stepper Motor
#define INVERT_X_DIR true

#define INVERT_Y_DIR false
#define INVERT_Z_DIR true
#define INVERT_E0_DIR false
Travel limits after homing
#define X_MAX_POS 200

#define X_MIN_POS 0
#define Y_MAX_POS 200
#define Y_MIN_POS 0
#define Z_MAX_POS 200
#define Z_MIN_POS 0
Feedrate and acceleration settings
#define HOMING_FEEDRATE {50*60, 50*60, 2.5*60, 0} // set the homing speeds (mm/min)
#define DEFAULT_AXIS_STEPS_PER_UNIT {80, 80, 4000, 100.52} // steps per unit for Solid Cube Direct Dr
#define DEFAULT_MAX_FEEDRATE {500, 500, 2, 25} // (mm/sec)
#define DEFAULT_MAX_ACCELERATION {4000,4000,100,1000} // X, Y, Z, E maximum start speed for accelerat
#define DEFAULT_ACCELERATION 1000 // X, Y, Z and E max acceleration in mm/s^2 for printin

#define DEFAULT_RETRACT_ACCELERATION 3000 // X, Y, Z and E max acceleration in mm/s^2 for retracts
Jerk values
#define DEFAULT_XYJERK 20.0 // (mm/sec)

#define DEFAULT_ZJERK 0.4 // (mm/sec)
#define DEFAULT_EJERK 2.0 // (mm/sec)
Download and Install Arduino IDE

Since Arduino is a popular board we will not go detail into this topic, there are plenty of
articles, how to, youtube video, books, etc. just do a google and find it yourself.
Download the Arduino IDE

Arduino - Getting Started
Program Marlin firmware to the RAMPS

Start Arduino IDE
Open file Marlin/Marlin.ino in Arduino IDE, then press compile and upload button in the
IDE tool bar.
Wait till the Marlin firmware is uploaded

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RepRap

Prusai3 Assembly Guide

RepRap Prusa i3 3D Printer Full DIY Kit in affordable price in India.

You can know more on http://reprap.org/wiki/About

Prusa i3 Project page: http://reprap.org/wiki/Prusa_i3

BOM (Bill Of Materials)

Laser Cut Parts, [6mm Acrylic] 1

All Metal Chilly Hotend Set 1

Threaded Rod M5 x 300mm (MS) 2

StepStick Stepper Driver 4

LM8UU Linear Bearing 10

GT2 Timing Belt 6mm x 65 cm 1

GT2 Timing Pulley 6mm x 20 Tooth 2

5x5 Aluminium Rigid Shaft Coupling 2

Fasteners: Screws, Bolts, Nuts, Washers 1 Pack

Assembling Prusa i3 Frame

Main frame and side frame assembling

Top Plate Assembling

Z-Motor Mount Assembling

Install the motor

Assembling Base/Bed Platform

Checkout animation video on how to Assembe base platform on youtube:

X,Y and Z axis Assembling

Base Platform Assembly 14

Base Platform Assembly 15

Base Platform Assembly 16

Base Platform Assembly 17

Base Platform Assembly 18

Base Platform Assembly 19

Base Platform Assembly 20

Base Platform Assembly 21

Base Platform Assembly 22

Base Platform Assembly 23

Base Platform Assembly 24

Prepare the RAMPS electronics

Assembling RAMPS and Arduino

Step Stick Assembly, note the direction of Trim Pots

Make sure your assembled electronics looks like the picture

RAMPS After Assembly

Configuration 1: Hotend (D10) + Fan (D9) + Heat Bed (D8)

Configuration 2: Hotend (D10) + Hotend (D9) + Heat Bed

Connecting Thermistor, Limit switch and Power supply

Connecting End Stops

Wire the power supply

Configure and Compile Marlin Firmware

Download Marling Firmware

Download Marlin from https://github.com/MarlinFirmware/Marlin

Configure Marlin Firmware for RAMPS and

In the extracted source, open Marlin/Configuration.h file with editor

Set the baudrate

#define BAUDRATE 115200

Set the MOTHERBOARD define to RAMPS

Set Name and UUID (Optional)

#define CUSTOM_MENDEL_NAME "Prusa i3"

Set no. of extruder's

Set the thermistor

Set MAX temperature limits

#define HEATER_0_MAXTEMP 230

Set PID values

#define DEFAULT_Kp 26.88

Sets direction of endstops when homing; 1=MAX, -1=MIN

Set the direction of XYZ and E axis Stepper Motor

#define INVERT_X_DIR true

Travel limits after homing