After building a Wolfstrap, designing my own printer, and building it, I had a couple of other design ideas going through my head.
After a while I thought to myself, there are quite a few designs out there and they all more or less are just a variant of each other.
So why spend weeks, months or a year trying to make/develop one more? Challange I guess is a very valid point, but I decided for now to have a closer look at the Prusa i3 instead.
I like the design that Prusa has come up with in regards to the single plate version. It looks sleek and is quite easy to build. It can be separated into 2 parts and therefore easier to transport as well.
After downloading the openscad files and checking out the ALU frame design I realised that this has got a lot of potential (for modifications and improvements, if you feel like it.)
On my first version of the i3 I used the frame as it is, as I wanted to check this design in regards to printing quality.
During my first build I modified some of the parts for my second i3, added some new parts and also changed the frame. I have not implemented all these changes yet as I design and modify as I go along. My first i3 which you can see in the photos below uses standard frame.
The most noticable change I have done is that I have got rid of the belts altogether. After having great difficulties finding GT2 belts and pullies, without paying way too much, I had had enough. I redesigned the parts to use braid fishing line. Yes you read that correctly. My version of the i3 uses Spectra Braid for both X and Y axis. If I wanted to I can still change the braid with belts but it involves changing the x-carriage and the belt holder under the bed.
It can’t get any cheaper than that and the best of all is that it works extremely well!
One of the benefits are that I can now print my own pulleys as well. Though pulleys are probably the hardest parts to print as they need to be very accurate.
I also decided that on my i3 I would use a Bowden extruder. The weight of a normal extruder setup is way to high and it really makes it hard to developing a multi nozzle setup due to weight. Sure it can be done but the weight of the motors are way to high for my liking.
I designed my own bowden extruder to test and it works quite well. There are a lot of good designs out there to use. I did my own as I needed a direct drive using 608 bearings and could not find one.
Then I designed a new hotend as well. This time I went for a stainless steel hot end. It worked first go. I did a slight modification and have already printed multiple complete set of parts for more i3′s, using my new i3 and nozzle. I only use ABS (will be testing some PLA later).
I had to do a lot of tweaking to get the bowden to work the way I wanted, a bowden is a different ball game altogether compared to a normal setup. And I am still tweaking it.
The quality of the parts coming off this machine is very good.
Will try to add some build details and info a bit later but for now here are some early photos:
And guess what? I have decided to stick to braid as it works fine!
This printer works very well, and it looks good, just look at this:
Ready to print another set of parts….