Mendel90 Dibond rear housing

thingiverse

As many enthusiasts as I have met, I began with a Mendel90. My printer was built according to nophead's GitHub files, modified due to part availability. When printing PLA, everything is fine, but when starting with ABS or other materials, a very slight smell of smoke can ruin the print. After scouring Thingiverse and various online resources, I couldn't find anything suitable for the Dibond version. However, my printer frame is made from 3mm aluminum sheets, which offers no significant difference. As I don't use a 300mm spool, the customized holder is slightly smaller; you can use one of the original holes for the covers if desired. If you want to use the larger covers, consider increasing the spool holder height by approximately 50mm. The enclosed holder is designed for a 12mm rod, but I've successfully used it with an 8mm rod and a bearing spool holder. I also employed a 3/8" carbon tube from kiting as my filament guide rod; feel free to substitute with whatever you find. Mount the guide in reverse to ensure the PTFE tubing runs smoothly to the extruder. The cover plates are made from corrugated cardboard, but you can opt for Dibond, Acrylic, or something similar with 3mm thickness if preferred - cardbox is merely the cheapest option. The only custom parts I designed were the covers and end caps; all other components are taken from the listed remix resources. You can find a suitable front housing with doors here: http://www.thingiverse.com/thing:755654. As of 2017-03-22, I've uploaded the latest update. A few pictures will be posted within the next month. Changes for V1.2 include corrected end cap scaling and modification to a bearing-supported spool holder due to entangled filament issues. Since this change, no problems have arisen, and the part spool holder has been customized for use with many spools (approximate 500g to 1kg capacity). As of 2015-04-06, I made small adjustments to the cover plates to rectify copy-paste errors - resulting in V1.1. **Assembly Instructions** You'll need the following parts for the cover: * 17 pcs cap screw M4x16 * 1 pc. cap screw M4x20 (for the rear fixing block) * 17 pcs. washer M4 x 9mm x 0.8mm * 1 set cover plates (see PDF or DWG) * 2 holes 4.5mm on left rear frame, as per attached drawing. For the filament guide: * 1 filamentfuehrung.stl * 1 rod approximately 8-9mm diameter and L=308mm long. * 2 cap screws M3x10 * 2 washers M3 x 7mm x 0.5mm * Drill two holes of approximately 3.5mm in the frames, as per your requirement. For the filament holder: * 2 filament_holder_20150322-final.stl. * 4 cap screws M4x16 * 8 washers M4 x 9mm x 0.8mm * 4 nyloc nuts M4 * A rod approximately 12mm in diameter and L=336mm long. * Drill four holes of approximately 4.5mm in the frames, as per your requirement. **V1.2 Update** You'll need these additional parts for the spool holder: * 2 spool\_holde\_dia60\_dia40\_h17.stl * 3 clip.stl. * Two bearings 608 (reusing old spool holders). * One rod approximately 8mm diameter and L=336mm long, with threads (instead of the original 12mm rod). For the fan guard: * 1 fan guard.stl * Four nut M4 to secure the original screws (longer screws may be required depending on your fan mounting) * Two wing nut M4 to secure the second fan guard. * A small piece of active carbon filter material from a cooker hood. Simply print and assemble; just use the printed guard as a reference for the filter holes. Drilling should be done with a soldering iron. Print all parts with 50% infill. Depending on the size of the washers used to level your print bed, it may be necessary to adjust the firmware end position (mainly in configuration.h) from #define Y_MAX_POS 100 to #define Y_MAX POS 98, to prevent contact between the bed and the back cover.