JP-440 Custom RepRap

thingiverse

Prologue ------------------- I've always dreamed of creating something with additive manufacturing, ever since I saw Jurassic Park 3 and its printed velociraptor vocal chambers. It sparked an idea in me - to print parts in my own basement. Fast forward 15 years, I bought my first 3D printer, a CR-10. Within a month, I knew I wanted another one. This time, I wanted it to be a challenging project that would teach me many things along the way. That's when I came up with the idea of designing my own 3D printer from scratch. Reality --------------------- If you're planning to follow my project at this scale, be warned - it won't be cheap. For smaller sizes, the cost may not drop enough to justify not buying an off-the-shelf model. This project is intended for larger format printers and those who want to learn how 3D printers are built and work. This project is not for the faint of heart, requiring a deep understanding of mechanics, materials, and technology. If you're not looking to reproduce my printer, feel free to browse the parts list to see if there's something useful for your custom setup. If your design is based on 2020 extrusion, I may have some helpful resources for you. When designing this project, I didn't leave enough room for the head, resulting in a printable area of around 375x375x375. The height would be higher with the uploaded top bearing mounts because mine currently uses an older version that restricts build volume. I expect a build volume of 375x375x400, easily maybe 410 on the Z-axis. Purchased Parts ------------------------- In the files is the parts list spreadsheet, which lists all the items I purchased for my printer and the prices I paid along with a link to each item's listing. Briefly, you'll need to buy all the electronics - steppers, hotends, endstops, bed heaters, controller, fans, etc. You'll also need the framing (2020 aluminum) and hardware to assemble. Printed Parts ------------------------- Most of a printer is not printed, but we print where we can. Briefly, the printed parts include things like the head assembly, filament mounting bracket, x and y axis alignment/structural brackets, all stepper mounts, and the extruder grippers. Design ------------------------- My design is inspired by the likes of the CR-10, Anet A8, Prusa i3, and the Tevo Tarantula. It's a Y-bed Z&X-head layout with dual Z and dual extrusion. From my selected parts: * I chose a 600w 12v bed setup that heats up in under 5 minutes. * I used the Duet3D board as the controller, but any compatible controller should work. * I went with E3D V6 clones, so if you diverge head bracket modifications will be required. * I opted for ethernet cable for the cabling of the printer to keep things tidy. * I'm not claiming this is a perfect design or a "better" one - it's simply my take on what I could make with my experience. It doesn't print flawlessly, but it works more than well enough. Dual spool filament holder made of PVC on the top The hardest part of the entire project was probably the bed carriage. It took me a solid 5-6 hours to cut and grind a sheet of 1/4 inch aluminum. I would recommend going thinner on the bed than I did, but this is as thin a carriage I'd want. Don't use the second leadscrew nut spot on the X-Axis adapter - it's not in alignment and is a poor design all around. I'm only using the top one and the bottom one is empty just the lead screw going through it. I plan on redesigning that entire adapter part. Still to come! ------------------- * Full assembly instructions * Videos of my printer at work * Constantly refining design (input/criticism welcome) Also, I plan on creating a mounting adapter for a Dremel 4000 to be mounted to the head for light-duty CNC routing, as well as throwing on a laser module for laser engraving. It should be fun!