5RAILS CORE XY 3D Printer

thingiverse

Functionally complete. Screw lengths and quantities in BOM may need adjustment. Specs: ===== MGN12 linear rails on all axes for accuracy and space savings. 5 rails are used- 1 for x, 2 for y, and 2 for z, hence '5RAILS'. The printer sports a healthy 300mm x 300mm x 350mm print envelope, a 500W heated bed using a 120VAC solid state relay, dual z non-cantilevered lift on TR8x8 trapezoidal leadscrews driven by single z stepper motor, dual e3D Titan direct drive (non bowden) extruders, non crossing X and Y belts in CORE XY (push-pull) configuration to minimize ringing and increase speed, and 2020 extruded aluminum frame with laser cut aluminum corner supports for rigidity. I have experimented with 3D printed supports, but frame was not stiff enough for my tastes. This design is meant to be rigid, fast, and use minimal printed pieces. Cost is ~$750 USD not including tax, shipping, and duties as applicable to your country. Full design CAD files are available in Onshape (you need a free account to copy the design and edit yourself). All design files are exportable to .stl. For convenience, I have downloaded and rotated the stl's and posted them to Thingiverse here. Onshape files are here. --------------------------------https://cad.onshape.com/documents/58c0e9de910b980f78db313a/w/f2cc9715f90baade4735c223/e/94a5242ec921dd91f2257e06 For bill of materials, latest will always be posted here: https://docs.google.com/spreadsheets/d/1Hk-xcSfI6vfVNKvCDCkBKN79KrJszzolMjrFaeewW4o/edit?usp=sharing For assembly, for now please consult the 3D model live in Onshape and the respective assemblies- frame, x, y, z, and e. This shows how the parts fit together. I will be creating an assembly guide, including mechanical, electrical, and software sections within the next few weeks. I suggest not shopping around for cheaper 'core' items: rails, leadscrews, extruders, 3d printer controller (re-arm for ramps, and RAMPS 1.4 SB), these are cost optimized already, and are known good quality- stainless rails and leadscrews, good tolerances, reliable electronics. Go cheaper at your own risk, potentially compromising the entire design. Updates and changes: ================== 8/21/2017: Added e3D v6 bowden mount option for those that do not want to use the e3D v6 Titan direct drive option. One or two bowden mounts can be attached to the existing X Extruder Mount frame. New parts for printing a single bowden mount are: 1 x X Bowden Mount- X Bowden Mount Back, and 1 x X Bowden Mount- X Bowden Mount Front. BOM has been updated to reflect the options of Direct Drive or Bowden, and what parts to print. 8/21/2017: Deleted X to Y Mount- X to Y Mount Bottom and X to Y Mount- X to Y Mount Top, as they should not have been separated into two pieces. Added X to Y Mount as replacement. 2 x X to Y Mounts should be printed, one for left side of X axis, and one for right side of X axis. BOM has been updated to reflect the X to Y Change. 8/21/2017: It appears that the 3D printed spacers for the 694ZZ bearings used for the Y axis idlers are not working out. Suggest using some 0.5mm H x 5mm ID washers with a small outside ~6-7mm OD, and stacking them (3 on top, two in middle, 3 on bottom). 8/21/2017: The Z axis continuous belt is too long for proper tensioning by about 150mm. The positioning of the Z idlers on the Z Idler Mount will re-positioned to take up the slack- I will not know the actual design until build/test this weekend. 8/21/2017: The z axis Z Bearing Mount may not be thick enough to position the z trapezoidal lead screws straight vertically. If it looks like the trapezoidal lead screw will be forced to bend, use some washers to space it correctly vertically. I will test positioning this weekend, and will repost a thicker Z Bearing Mount if it looks like it is required. 8/28/2017: The Z Bed Mounting has changed- please see the Z section assembly in Onshape for changes and how components are assembled. There is no longer a requirement for countersunk holes in the build plate or holes in the heat bed mat (oversight!)- instead two M5 x 15mm OD washers are used to 'sandwich' the build plate from the outer edge, compressed and held by a spring below the build plate. Any large flat washers >15mm OD should do as long as they are not flexible and are heat resistant, although you want the ID to be about 5.3mm (to fit an M5 bolt). Added 'Z Bed Mount.stl' to the printable files. You will need to print out three for a complete bed mount. The three 2020 aluminum extrusions used for the bed mount have been shortened to accommodate the changes to 127mm (+Y) and 151mm (-X-Y, +X-Y). The center hole in the end of each extrusion requires tapping for an M5 screw. BOM has been updated with changes.