Folger Technologies i3 2020 Full Lead Screw Upgrade on all axis

thingiverse

Folger Technologies i3 2020 Full Lead Screw Upgrade on all axis. 1st Thanks to GarRemMash (http://www.thingiverse.com/GarRemMash/about) for the original Z & X kit. This kit got me thinking of that all that was needed was to add the Y Axis to make full lead screw machine. The result is a full 190 x 190 x 180 mm print area. This upgrade is not for the novice. The upgrade just about takes the whole kit apart, re-squares and re-assembles; please plan ahead accordingly. Check your parts, parts lists, and be sure you have everything (else you'll be borrowing a friends printer for parts) ** Do this upgrade at your own risk, for additional support join the Folger Technologies Facebook page: https://www.facebook.com/groups/Folgertech3dPrinters/ Videos in action:https://www.facebook.com/James.M.Beam/videos/10207023617811768/https://www.facebook.com/James.M.Beam/videos/10207034929934564/ Important note: The lead screw drive limits build speed to a nominal 50 mm/s travels / on some parts you can go to 60 mm/s. I have tried going above with very mixed results. For example, I have had some parts do great at 75 mm/s where others will skip and fail. If you have ANY reservations about this upgrade I definitely do not recommend it. Print Settings Printer: Folger Tech i3 2020 Alum Rafts: No Supports: No Resolution: 0.2 mm Infill: 100% for rigidity Notes: I used ABS for most parts; however, PLA will work just fine. Post-Printing General Notes Be sure to trim & edge parts, as well as test fit before major disassembly. I found keeping the steppers at the top, with the extensions, with the 608ZZ bearings, then on the lower plate side adding a thrust bearing, then a collar to clamp the screw the best way to stop the flex coupling from stretching (in fact with this setup, it cannot). It's more expensive (and time consuming to setup); but, I get great 0.2 mm layers every time. This also solves a lot of the bed leveling issues too as Z is locked (does not change with up / down movements). Assembly for the Z-Axis setup needs thrust bearings installed in this order:: Stepper motor Extension mount Flex coupling 608ZZ bearing mount plate thrust bearing collar to clamp When installed correctly, the flex coupling will not expand or contract with Z axis movements adding more accuracy to your prints. Here are few photos of prints made with this setup: https://www.instagram.com/p/BMPxU5_hMjh/https://www.instagram.com/p/BMHpq-6hyvj/https://www.instagram.com/p/BLziwdxhaWt/https://www.instagram.com/p/BLpxrsVhaCo/https://www.instagram.com/p/BM33Nh_BFI1/https://www.instagram.com/p/BLXHkCdBe9f/https://www.instagram.com/p/BJVjv2-BPqR/https://www.instagram.com/p/BJUYjxiBbJb/https://www.instagram.com/p/BIxpfAuBc5m/ How I Designed This Benefits I see are: 1) increased accuracy & precision the lead screws have no play & move more with each rotation than a GT2 belt Igus bearings add to the above able to get +/- 0.05 (or less) dimensions on a 20 mm test cube 2) less ringing in the layers, lead screws are quieter/less vibration than a GT2 belt 3) allows for heavier "ends" so one of my plans was to add a laser cutter option or even a mini-mill via a Dremel with a flex shaft to the cutting tool 4) bonus feature is increase build Z height (can get this with a belted upgrade as well) - mine happens to maximize this to 180 mm (technically, I can go 184 mm, but that is really close to crash at the top) 5) not fully tested, but speeds are as fast as a belt; maybe faster. This requires more tweaking of firmware settings and stepper motor voltages - could spend weeks driving to ultimate levels. Not my intent as #1 was the prime objective, accurate parts. 6) Well someone had to do it . . . Parts! 1st you'll need the parts in this post Additionally you'll need: Lead Screws 2x 300 mmhttps://folgertech.com/products/300mm-lead-screw-3d-printer-z-axis-lead-screw-300mm-lead-screw-8mm-screw-pitch 2x 400 mmhttps://folgertech.com/products/400mm-lead-screw-3d-printer-z-axis-lead-screw-acme-lead-screw-8mm-screw-pitch 1X 8mm Brass Lead Scew Nut 1x (needed for anit-back lash Y axishttps://folgertech.com/collections/lead-screws/products/8mm-brass-lead-screw-nut Bearings for Y Axishttps://folgertech.com/products/2pcs-self-align-8mm-bore-inner-ball-mounted-pillow-block-insert-bearing-kp08 4x Stepper Motor Couplingshttps://folgertech.com/products/5mm-to-8mm-flexible-coupling-od-19mm-x-25mm-for-cnc-and-prusa-3d-printers Z Axis Motor Risers:http://www.thingiverse.com/thing:1288802 Corner braces:http://www.thingiverse.com/thing:1387216 My Fan bracket & Servo Arm for Z probehttp://www.thingiverse.com/thing:1481551 Blower Duct fromhttp://www.thingiverse.com/thing:976189 Dual Bearing mount for Y table:http://www.thingiverse.com/thing:1120328 All stepper motors replaced with this one:https://smile.amazon.com/gp/product/B0196FH94E Thrust washers and collars 4x of these: https://smile.amazon.com/gp/product/B00DN5KYT6 1x (set of 4) of these: https://smile.amazon.com/gp/product/B0063KWIYC/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1 12 Igus Bearingshttps://folgertech.com/collections/bearings/products/igus-rj4jp-01-08-8mm-linear-bearing-to-replace-lm8uu 6x 8MM ID Skate Bearings:https://smile.amazon.com/gp/product/B002BBGTK6 Optional: (anti-backlash nut & spring) will need 3xhttp://www.ebay.com/itm/322089168774 If used, the part "Z_leadscrew_antibacklash_rev2" will need to be mirrored for 1x One being left side, the other being right side. Also, the Z nuts will require to be trimmed with a cut off wheel to fit. I've not listed every 3mm / 4mm screw and T-nut. But plan for several. ** You'll need to review the assembly and make a check list for this. Here are a few to review:https://folgertech.com/products/12-x-lm8uu-4-x-608zz-2-x-623zz-bearing-kit-prusa-i3-rework-reprap-3d-printerhttps://www.amazon.com/gp/product/B014ONCP88/ref=oh_aui_search_detailpage?ie=UTF8&psc=1https://www.amazon.com/gp/product/B010CRN2SC/ref=oh_aui_search_detailpage?ie=UTF8&psc=1https://www.amazon.com/gp/product/B003KWER3Q/ref=oh_aui_search_detailpage?ie=UTF8&psc=1https://folgertech.com/products/four-4-internal-cast-2020-corner-bracket-fittings-industrial-aluminumhttps://folgertech.com/products/four-4-2020-corner-bracket-fittings-industrial-aluminum Photos should should show the remaining notes. Note the Power supply and ramps are moved to the outside 2020 frame so the lower brace arm can install. Note: I remixed the Y-Axis thread holder from here:http://www.thingiverse.com/thing:718386 2017-01-01 UPDATE FARGKENOB created a great Y Axis Stepper Motor mount here:http://www.thingiverse.com/thing:2007186 I have updated to this part & suggest any builders do the same. Simply cut the extra spool holder 2020 pc in half (~70.6 mm) and mount per the pictures shown shown here: http://www.thingiverse.com/make:283086 TNSI created a better Z-Axis Leadscrew Guide also here:http://www.thingiverse.com/thing:1937927 I have also updated to this part and recommend this part be used instead of the "z_axis_guide_bearing_leadscrew" as it can be installed/removed/replaced without removing the guide rod. Some more details on how the bearings go together: Z axis (top to bottom) is stepper motor->shaft couple->skate bearing (shaft couple rests on the skate bearing), bracket, thrust bearing, collar. X Axis (right to left) is stepper motor->shaft couple->thrust bearing (shaft couple rests on the thrust bearing)->skate bearing->right mount->skate bearing->collar ->carriage