i3 X Axis Linear Rail System

thingiverse

While still usable, this is a work in progress designed to replace the original 8mm smooth roads on my Hesine m505 with 400mm MGN12 linear rails and 10mm wide belts. This design incorporates a floating X axis idler to help reduce Z wobble artifacts. Currently it uses an old fan duct design and is also compatible with my Z endstop adjuster. I will later update this for use with 450mm rails, which I should have ordered, and different pulley sizes. Note that this is designed for printers with a spacing of 22mm between lead screw and smooth rod centers. A revised version using LM10 rods is now available. A detailed bill of materials includes: mk8 extruder idlers, springs, M3 bolts supplied by the manufacturer; two 400mm MGN12 linear rails, two H blocks; 16/20T G2T gear with a 5mm bore and an idler pulley; one M5x20 bolt with nut; assorted M3 x 5/10/15/20 screws and nuts; one M3 x 40mm screw; small piece of PTFE tube. Print settings used are as follows: RepRap brand printer, i3 model, no rafts or supports necessary, resolution set to 0.25MM, infill at 15%. Note that two perimeters/shell with three bottom and four top layers were used for added strength/stiffness. Some parts may require supports for optimal results. Post-printing instructions: ensure excellent layer bonding and that the rails fit snugly in place. There is a small built-in tolerance, but warping or poor overhang performance can cause the opening to be too small and inserting the rails will split the part. You may need to drill out 3mm (3.3 design) holes and tap 2.5s if they come out undersized.