Fab@Home:Model2Assembly

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Watch this video on how to make your Model 2

Assembly diagrams available for:

In development:

  • Bridge/Carriage
  • Deposition Tools
  • Z-Axis


Contents

Prep the parts

  • Thermoplastic Inserts
    • Place the [1/4-20 inserts] into the chassis bottom from above
    • Place the [M4-.7 inserts] into the tensioner fronts
    • Place the [M2.5-.45 inserts] into the z table back, ensuring it is flush with the surface
    • Place the [M2.5-.45 inserts] into the carriage front
    • Place the [M2.5-.45 inserts]into the bridge bottom from above
    • Place the [M2.5-.45 inserts] into 2 belt clamps. These belt clamps have 2 wide holes.
    • Place the [6-32 inserts] into the pillow blocks
    • Place the [6-32 inserts] into the z table support
    • Place the [6-32 inserts] into the Tool mount plate
    • Place the [6-32 inserts] into the Tool back plate
    • Place the [6-32 inserts] into the Tool mount screw plate

NOTE: for tips on how to insert Thermoplastic Inserts, go here.

  • Bearings
    • Place the [6.02mm Bore 14.5 mm Panel Hole Bearing] into the chassis right side
    • Place the [6.02mm Bore 14.5 mm Panel Hole Bearing] into the x drive shaft supports
    • Place the [10.02mm Bore 15.9mm Panel Hole Bearing] into the Z top
    • Place the [10.02mm Bore 15.9mm Panel Hole Bearing] into the Z bottom
    • Place the [10.02mm Bore 15.9mm Panel Hole Bearing] into the bridge front plates
    • Place the [10.02mm Bore 15.9mm Panel Hole Bearing] into the bridge back plate
    • Place the [10.02mm Bore 15.9mm Panel Hole Bearing] into the carriage side plates
    • Place the [4mm Bore Diameter Ball Bearing] into the tensioner sides, ensure half are from one side, and half are from the other.
    • Place the [ 4mm Bore Diameter Ball Bearing] into the bridge front plate
    • Place the [ 4mm Bore Diameter Ball Bearing] into the z shaft support
  • Motors
    • Secure a [3mm (HTD) Pitch, 10 Teeth, Polycarbonate timing pulley] on 2 [SM062 motors]
    • Secure a [4/6mm coupler] to a [SM062 motor]
    • Screw a [SM062 motor] with the coupler onto the x axis motor support
    • Screw a [SM062 motor] with the pulley onto the z axis motor support
    • Screw a [SM062 motor] with the pulley onto the Bridge back
  • Cutting Parts
    • Cut the [Metric Class 4.6 Plain Steel Threaded Rod, M3 size, 1 meter length, .5 mm Pitch] into two lengths of 170mm.

Making sub-assemblies

  1. X,Y,Z tensioners
    1. Match 2 tensioner sides that have bearings on opposite sides.
    2. Place a tensioner front and the sides together with the top of the insert facing inwards.
    3. Slide in a [3mm (HTD) Pitch, 10 Teeth, Polycarbonate timing pulley]
    4. Slide a [4 Diameter, 35mm Long shaft] through the bearings and pulley
  2. Carriage
    1. Put the carriage cross plate into the front plate with the inserts facing the cross plate
    2. Attach the carriage sides with the bearings facing outwards
    3. Attach the carriage bottom.
  3. Bridge
    1. Attach the bridge bottom and back.
    2. Attach the inner sides
    3. Attach the outer sides and front plates
    4. Put a [4 (-.004/-.012) Dia, 35mm Long Shaft] through the bearing on the left side of the bridge and into the motors pulley
  4. Z table
    1. Attach the z top and bottom plates to the z back plate. Ensure the inserts face outward
    2. Attach the z side plates
    3. Place the middle strut between the top and bottom plates
    4. Attached the z support plate
    5. Secure the middle plate
    6. Attach the z table plate
  5. Chassis
    1. Attach the cross plates to the back plate
    2. Attach the top plate to the back plate
    3. Attach the cross plates to the top
    4. Attach the left side to the back and top plate
    5. Attach the right side to the back and top plate
    6. Attach the front to the top left and right plates
    7. place the bottom to the left right front and back
    8. Attach the z axis motor support and shaft support to the back and bottom
    9. Screw the bottom to the adjacent plates.
    10. Put a [4 (-.004/-.012) Dia, 35mm Long Shaft] through the bearing on the z axis support cross plate and into the z axis motor’s pulley.
    11. Attach the [Snap-Hub] support plates to each other and the top and left side.
  6. Displacement Tool
    1. Screw two [SM062] motors to the drive interface plate, ensuring that the flat side of the motor shaft faces through the plates long cutout.
    2. Slide the syringe holder plate over the motors
    3. Snap the plates into one side plate
    4. Snap the lower drive support plate into that side
    5. Snap the other side together
    6. Place the syringe support plate into the syringe holder plate
    7. Attach the bottom plate to the support and side plates
    8. 2x Put a [Round Knurled Thumb Nut, M3 screw] inside [6mm bore, 28mm pitch dia. 16mm hub dia. Gear] and tighten the set screw
    9. Attach the [4mm bore, 28mm pitch dia. 16mm hub dia. gears] to the snap motors
    10. Put the Gears + nuts into the drive interface plate
    11. Put a [3 mm Bore, 6mm Outside Dia. Ball Bearing] in the gears + nuts
    12. Attach the upper drive support plate.
    13. Screw a cut length of threaded rod through the gears + nuts.
    14. Put 2 nuts on the top of each length of rod and tighten so they are locked
    15. Put 1 nut on the bottom of each rod with enough space to screw one exactly one more nut. (Optional: Glue the nut in place using cyanoacrylate.)

Putting it all together

  1. X drive
    1. Slide the [400mm Long, 6mm shaft] from the right side into the printer. Before reaching the first cross plate put on a [G T2 (3mm) Pitch, 18 Teeth, Polycarbonate timing pulley]
    2. Slide down until you reach the couple. Back it out a bit and put on another T2 [(3mm) Pitch, 18 Teeth, Polycarbonate timing pulley]
    3. Secure the set screws of the couple and pulleys.
  2. Chassis + Z table
    1. Slide two [10 (-.005/-.014) mm Dia, 300mm Long Shafts] up thorough the bottom plate.
    2. Put the Z table onto the shafts
    3. Slide the shafts up through hthe top plate
  3. Bridge + carriage
    1. Slide two [10 (-.005/-.014) mm Dia, 300mm Long Shafts] through the bridge from the left side.
    2. Place the carriage on the shafts
    3. Slide the shafts into the right side, but not going past the right side plate.
  4. (Chassis+ Z -Table) + (Bridge + carriage)
    1. Slide two [10 (-.005/-.014) mm Dia, 375mm Long Shafts] through the back plate.
    2. Place the Bridge onto the shafts
    3. Place the pillow blocks onto the shaft
    4. Slide the shaft flush with the front of the front plate.
    5. Screw the pillow blocks to the front plate
  5. Mounting the tool
    1. Slide the quick mount tool into the carriage from the top, and secure with a 6-32 thumbscrew

Wires, belts, and calibration

  1. X Belts
    1. Clamp a [3 mm GT2 Pitch, 6mm Wide Belt] to the back of the bridge on each side
    2. Wrap it around the x drive shaft pulleys
    3. Wrap it around the x axis belt tensioners
    4. Secure the free end to the bridge with sliding belt clamps
    5. Screw the tensioners to the front plate with [M4 16mm Screws]
    6. Cut belt to length
  2. Y belt
    1. Secure a [3 mm GT2 Pitch, 6mm Wide Belt] to left side of the carriage using a belt clamp(w/ inserts)
    2. Wrap the belt around the motor
    3. Push the belt through the right side and around the y tensioner.
    4. Secure the free end with a belt clamp(w/ insert) to the carriage.
    5. Cut the belt to size
    6. Screw the tensioner to the side of the bridge using an [M4 16mm long Screw]
  3. Z belt
    1. Put spacer up to Z table back
    2. Secure a [GT2 (3mm) 600mm 9mm wide Belt] to the Z back plate with a sliding belt clamp. Use the [M2.5 16mm length screw].
    3. Wrap it around the z axis motor
    4. Warp it around the z axis tensioner
    5. Secure it to the z back plate with a slidding belt clamp
    6. Cut to size
    7. Screw the tensioner to the support top plate.
  4. Wires
    1. Put the hub into the space on the top left of the printer
    2. Wires on the hub go in the following order x, y,z,tool 1, tool 2
    3. Put cat5 cables into the tool head and bend them back behind the tool and feed them into the space between to toll back plate and the carrage front plate.
    4. Secure the cables with zip ties to the hole on the top left of the bridge
    5. Combine extra lengths of cable together and zip tie them to the back plate through the holes on the left side of the back plate.
  5. Tensioning
    1. To tension belts tighten the screws attaching the belt tensioner to the chassis.
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