Reprap Prusa Mendel Build Manual MASTER V2.pdf

LM8UU Prusa Mendel Build Manual

The programs supplied and referenced in this manual are free software: you can redistribute them and/or modify them under the terms of the GNU General Public License

as published by the Free Software Foundation, either version 3 of the License, or (at your option) any later version. These programs are distributed in the hope that they will

be useful, but WITHOUT ANY WARRANTY; without even the implied warranty of MERCHANTABILITY or FITNESS FOR A PARTICULAR PURPOSE. See the GNU General

Public License for more details. You should have received a copy of the GNU General Public License along with these programs. If not, see http://www.gnu.org/licenses/ .

A step by step guide for building your Prusa Mendel 3D Printer Kit.

The following instructions will take you through every step to build and commission your Prusa Mendel

3D printer. All the parts required are included in your kit. We recommend you read through the complete

manual to familiarize yourself with the process before starting. We also recommend you read the

following important points about your kit and the parts it contains.

Plastic Parts

All our plastic parts are printed on the same printers that you will be building. The parts are built at

varying densities to suit their application. Some are required to be stronger than others.

You should take special care when inserting bearings or nuts into plastic part recesses. Some parts

have more fragile areas. When inserting bearings ensure the part is held ﬁrmly on a ﬂat surface, ensuring

there is no force on fragile areas. Then push the bearing into the recess, increase the force until the

bearing clips into place. If you cannot get the bearing in place, using a pair of large pliers and a small

amount of force should ensure they go all the way in, always ensure you keep the bearing level and

avoid pushing in at an angle.

Plastic parts will wear over time. You should regularly follow the the maintenance tips in the manual to

ensure your printer remains reliable. We recommend that if your ﬁrst purpose is not to build yourself or a

friend a second printer then you should print a spare set of parts for your own. This will help you in the

future should a critical part wear out. This is also a great way to familiarize yourself with the print

process and all the ﬁles you need are included on the CD-Rom.

This manual is available to view and download as a pdf on our website http://www.nextdayreprap.co.uk

Health & Safety

This is a kit of components for assembly into a 3D Printer by the end user. Building and using the printer is

potentially very dangerous as it involves electricity and high temperatures.

Building the printer will require a certain amount of physical dexterity, common sense and a thorough

understanding of what you are doing. We have provided this fully comprehensive build documentation to

enable you to build your Prusa Mendel 3D Printer Kit in a safe manner, we have pre assembled many of the

more complicated components, such as the electronics to make it easier for you.

However ultimately we cannot be responsible for your health and safety whilst building or operating the

printer, with that in mind be sure you are conﬁdent with what you are doing prior to commencing with building

or buying. Read all of the manual to enable you to make an informed decision.

Building and operating involves electricity, so all necessary precautions should be taken and adhered to, the

printer runs on 12V supplied by a certiﬁed power supply, so you shouldn’t ever have to get involved with

anything over 12V but bear in mind there can still be high currents involved and even at 12V they shouldn’t be

taken lightly.

High temperatures are involved with 3D Printing, the Extrusion nozzle of the hot end runs at 230°C, the

heated bed runs a 110°C and the molten plastic extruded will initially be at around 200°C, so special care and

attention should be made when handling these parts of the printer during operation.

We wouldn’t recommend leaving your printer running un attended, or at least until you are conﬁdent to do so.

We cannot be held responsible for any loss, damage, threat, hurt or other negligent result from either building

or using the printer.

Contents - Reprap Prusa Mendel Build Manual

1.0

Bill of Materials

1.1

Check Kit Contents & Familiarize yourself with the kit components

2.0

Frame Assembly

2.1

Parts Required

2.2

Assembly

3.0

Y Axis Assembly

3.1

Parts Required

3.2

Assembly

4.0

X Z Axis Assembly

4.1

Parts Required

4.2

Assembly

5.0

Y Carriage Assembly

5.1

Parts Required

5.2

Assembly

6.0

Motor/Belt & Endstop Assembly

6.1

Parts Required

6.2

Assembly

7.0

Build/Heated Bed Assembly

7.1

Parts Required

7.2

Assembly

8.0

Extruder Assembly

8.1

Parts Required

8.2

Assembly

3.3

Hot End Connection

9.0

Wiring

9.1

Parts Required

9.2

Completing Connections

9.3

RAMPS Diagram

9.4

RAMPS Board Connections

10.0

Computer setup

10.0

Hardware Driver Installation

10.1

Hardware Setup & Connection.

10.1.2 Ardunio Driver - Windows XP Installation

10.1.3 Ardunio Driver - Windows 7 / Vista

10.2

Arduino Software Installation

10.2.1 Ardunio Software - Windows XP Installation

10.2.2 Ardunio Software - Windows 7 / Vista Installation

Contents - Reprap Prusa Mendel Build Manual

10.3

Python Environment & Dependencies Installation

10.3.1 Python Environment & Dependencies - Windows XP Installation

10.3.2 Python Environment & Dependencies - Windows 7 / Vista Installation

10.4

Pronterface Installation

10.4.1 Pronterface/PrintRun- Windows XP Installation

10.4.2 Pronterface/PrintRun - Windows 7 / Vista Installation

10.5

Skienforge Installation

10.5.1 Skienforge - Windows XP Installation

10.5.2 Skienforge - Windows 7 / Vista Installation

10.6

Testing Software & Communicating With the Printer

10.6.1 Connecting Hardware & Testing - Windows XP

10.6.2 Connecting Hardware & Testing - Windows 7 / Vista

10.7.0 Firmware Installation

10.7.1 Flashing Firmware, Test & Comms - Windows XP

10.7.2 Flashing Firmware, Test & Comms - Windows 7 / Vista

10.8

Firmware Variables

11.0

Commissioning & Calibration

11.1

Hardware Setup & Connection.

11.1

Frame Levelling

11.2

Bed Levelling

11.3

Endstops

11.4

Pololu Stepper Driver Calibration

11.5

Hot End

11.6

Heated Bed

11.7

Loading Filament

11.8

Removing Filament

11.9

Changing Hot Ends

11.10

Printing a Test Print

12.0

Maintenance

12.0

Health & Safety

12.1

Axis Lubrication

12.2

Hot End & Nozzle

12.3

Nuts & Bolts

12.4

Extruder & Gears

12.5

Electronics

12.6

Pulley Grub Screws & Belt Tensions

12.7

Build Surface

12.8

Bed Leveling

12.9

Plastic Parts

12.10

Bearings

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