Mendel Max 3 d Build Manual

3D BUILD MANUAL

3DFACTORY MENDELMAX 1.5

SCAN TO DOWNLOAD

3dfactory Mendelmax 1.5 3D Build Manual

by 3dfactory LLC

Copyright c 2014 3dfactory LLC

Permission is granted to copy, distribute and/or modify this document under the terms

of the Creative Commons Attribution-ShareAlike 3.0 Unported license (CC BY-SA 3.0).

For more information, call +1-347-631-8060 , email:[email protected] or go to

www.makea3dfactory.com

WWW.MAKEA3DFACTORY.COM

5

TABLE OF CONTENTS

TABLE OF CONTENTS

PREFACE

BUILDING YOUR MENDELMAX 1.5

BILL OF MATERIALS

6 PREFACE

ACKNOWLEDGMENTS

Being an open source project means there are many contributors working on and improving designs.

These Makers release all their hard work via an open source license. These designs are free for the pub-

lic to use. The least we can do is acknowledge their hard work.

The most important contributor is Adrian Bowyer, the creator of the RepRap project. Without him, the

Maker Movement would not be as strong as it is today. For more information on Adrian Bowyer and the

RepRap project visit www.adrianbowyer.net or www.reprap.org

The second most important Maker is the inventor of the Mendelmax himself, Mike Payson. Mike Payson

took inspiration from the Reprap Prusa and created a design that was stronger, more hackable and more

aesthetically pleasing. He has been a very active contributor in the open source community since creating

the Mendelmax. For more information on Mike Payson and his products visit www.makerstoolworks.com

We would also like to acknowledge Josef Prusa who took the Mendel 3D Printer and created an easier

and more affordable Prusa. Josefs design and Gary Hodgsons visual instruction's made the Prusa a

starting point in many peoples 3D printing endeavor. For more information on Josef Prusa and Gary

Hodgson visit www.reprap.org/wiki/Prusa_i3 or www.GaryHodgson.com For anyone else who has con-

tributed we would like to sincerely thank you for all your hard work.

Below are the sources for all the STL parts included in this build manual:

Left & Right Lower Vertex

Left & Right Upper Vertex

Z Motor Mount

Left & Right Z Motor Support

Z Upper Vertex

Y Idler Tensioner

Y Tensioner Mount

Y Motor Mount

X Brace w Logo

X Brace

Y Brace

Z Rod Clamp

Y Rod Clamp

hp://www.thingiverse.com/thing:20355

Y Rod Holder

Y Setting Jig http://www.thingiverse.com/thing:12645

Extruder http://www.thingiverse.com/thing:18379

Extruder Idler http://www.thingiverse.com/thing:17030

Large Extruder Gear

Small Extruder Gear http://www.thingiverse.com/thing:10707

X-end Motor

X-end Idler http://www.thingiverse.com/thing:34326

Y-carriage

Y Belt Clamps http://www.thingiverse.com/thing:23880

http://www.thingiverse.com/thing:26472 Spool Holder

X Carriage https://github.com/josefprusa/PrusaMendel

7

INTRODUCTION

PREFACE

Open source projects tend to involve parts and designs from all over the world. For this reason

documentation is usually scarce. For this reason we have decided to try and make the easiest build guide

for our Mendelmax kits. We Figured a colorful 3D build guide was the best choice. The easier it is to build

your own 3D printer the more people can take advantage of this awesome technology.

To make your build even easier, we created a 3D model for each step of your build. That way if the pic-

ture or description is not clear enough you can simply open the model for that step and inspect further.

The first step is to gather all your items and compare them to our Hardware BOM and Plastic parts check-

list. Make sure you have everything to get started. If you received a kit from us and are missing some-

thing send us an email, [email protected] . If you self sourced the parts make sure you order

everything you need.

Next, read through the build guide to get a basic understanding of the build. I would recommended prep-

ping the parts prior to getting started. For most of the M3 holes (excluding any in chapter 6) drill them

out using an M3 or 1/8 drill bit. Any vertical nut traps that need be reamed out should be done now as

well. This will ensure your build goes quickly and effortlessly.

Here is a list of recommended tools to make the build easy as possible:

Soldering iron

60/40 solder

Wire strippers/cutters

Drill

Various drill bit sizes

Level

Xacto or some other hobby knife

Dremel mototool or some other tool for removing burs and excess

plastic put into holes during manufacturing

Hobby grade medium thickness super glue. Regular super glue is not

sufficient

Caliper: digital or analog, metric preferred

Voltmeter/DMM

Verified level working surface

Torque wrench, inch pounds. Bigger screws tighten to no more than 15

inch pounds. Smaller screws, 8 inch pounds.

(Thanks Ben!)

8 PREFACE

3D Printed Parts

2x Upper Vertex

2x Z Motor Mount

1x Extruder

1x Extruder Idler

1x Large Extruder Gear

1x Small Extruder Gear

1x Y Idler Tensioner

1x Y Tensioner Mount

1x X-end Motor

1x X-end Idler

1x X Carriage

1x Y Rod Setting Jig

2x Y Rod Holder

1x Y Carriage

1x Y Carriage Spacers

1x Y Motor Mount

2x Spool Holder

1x X Brace w/Logo

3x X Brace

2x Y Brace

4x Z Rod Clamp

4x Y Rod Clamp

2x X Belt Clamp

1x Y Belt Clamps

2x (4 Total) Lower Vertex Left & Right

2x (4 Total) Upper Vertex Left & Right

2x (4 Total) Z Motor Support

Left & Right

2x 8mm

1x 10mm

Endstops

9

PREFACE

10

11

12 LOWER FRAME

1

Step 1

ASSEMBLING THE

LOWER FRAME

13

Plastic Parts

Hardware

Prepare: 1

4x 300mm Extrusions

28x M5x10 SH

28x #10 Washer

56x M5 T-Slot Nut

4x 420mm Extrusions

2x (4 Total)

Lower Vertex

Left & Right

LOWER FRAME

14 LOWER FRAME

1 1

2

Attach a right lower vertex to the tapped end of 2 300mm extrusions using 2x M5

screws and 2x #10 washers.

Insert t-slot nuts into the extrusions as follows:

Upper 300mm Extrusion

Front 2

Rear 2

Top 2

Bottom 0

Lower 300mm Extrusion

Front 4

Rear 2

Top 0

Bottom 0

15 LOWER FRAME

1 3

4

Attach a left lower vertex to t he opposite end using 2 M5x10s and 2 #10 washers

Secure 4 M5x10s w/ washers through the front holes into the t-slot nuts in the extru-

sions.

16 LOWER FRAME

1 5

6 Repeat steps 3-4

Repeat steps 1-2 with the remaining plastic parts and extrusions but follow the follow-

ing t-slot placement

Upper 300mm Extrusion

Front 3

Rear 2

Top 2

Bottom 0

Lower 300mm Extrusion

Front 3

Rear 2

Top 0

Bottom 0

17

Take the front & back pieces made from the earlier steps and use the 2 420mm extrusions

to connect them using 6 M5x10 screws w/washers.

LOWER FRAME

1 7

8

Take 2 420mm extrusions and insert t-slot nuts as follows:

Upper 420mm Extrusion

Front 4

Rear 0

Top 2

Bottom 0

Lower 420mm Extrusion

Front 4

Rear 0

Top 0

Bottom 2

18

Repeat step 8 with the remaining 2 420mm extrusions

LOWER FRAME

1 9

10

Take the remaining 2 420mm extrusions and insert t-slot nuts the same as step 7 but

reverse right and left:

Upper 420mm Extrusion

Front 0

Rear 4

Top 2

Bottom 0

Lower 420mm Extrusion

Front 0

Rear 4

Top 0

Bottom 2

19 LOWER FRAME

1 FRONT REAR

TOP BOTTOM

SIDES

20

2

Step 2

ASSEMBLING THE

Y-AXIS

Y-AXIS

21

Plastic Parts

1x Y Carriage

Hardware

Prepare: 2

Y-AXIS

1x NEMA 17

Motor

2x 420mm 8mm

Smooth rod

2x M3x6mm SS

5x M3x25mm SH

2x M3x30mm SH

6x M3x45mm SH

12x M5x10 mm SH

9x M5x16mm SH

4x M5x25mm SH

13x M3 Nut

6x M5 Nut

10x #10 Washer

4x Spacer

3x LM8UU Bearing

1x GT2 Pulley

2x Aluminum

Plates

1x Kapton Heatbed

1x Y Idler

Tensioner

1x Y Tensioner

Mount

1x Y Belt Clamp 4x Y Rod Clamp

1x Y Motor

Holder

2x Y Rod

Holder

1x Y Carriage

Spacers

1x Y Rod

Setting Jig

22

Start by preparing the parts prior to installation. Connect the Y-idler tensioner to the Y-

idler mount using 2 M5x10mm and 2 M5 thin nuts. Take a M8x30mm socket head

screw and pass it through a M8 washer, 2 608ZZ bearing, and another M8 washer.

Close it off with an M8 nut.

2

Y-AXIS

Take a NEMA 17 motor and secure the GT2 pulley as shown using 2 M3x6 set screws.

Make sure one of set screws is lined up with the flat on the motor. Attach the NEMA

17 motor to the Y motor holder using 2 M3x10 socket head screws.

1

2

23

Loosely attach the Y rod clamps to the Y rod holder using 4 M5x16 socket head screws

and 4 M5 thin nuts. Repeat this step for the other Y rod holder and Y rod clamps. Dont

tighten them all the way down since we still need some room to insert the 8mm

smooth rods.

2

Y-AXIS

Carefully insert 3 LM8UU bearings into the Y carriage. Dont stress the clamps too

much while inserting the bearings. Secure them in place using 3 M3x25 socket head

screws and 3 M3 nuts.

3

4

24

Loosely attach the previously assembled Y idler tensioner to the front of your base us-

ing 2 M5x10 socket head screws with 2 #10washers. Do not worry about the position

just yet.

2

Y-AXIS

Loosely attach the NEMA 17 motor and motor holder to the back of the base using 2

M5x10 socket head screws. Again do not worry about the exact placement.

5

6

25

Use the Y Rod Setting Jig to line up the Y Rod Holder. Attach the Y Rod Holder using 4

M5x10mm socket head screws with 4 #10 washers. Repeat this step for the opposite

side.

2

Y-AXIS

Carefully insert 2 8mm smooth rods through the Y Rod Holder from the front. Take

your Y Carriage and pass the smooth rod through the bearings as shown and then into

the Y Rod Holder mounted in the back of the printer. Tighten all 8 Y Rod Clamps secur-

ing the smooth rods in place.

7

8

26

Cut a 1168mm belt and wrap one end around the Y carriage as shown. Insert 2

M3x30mm socket head screws with #6 washers (not shown) through the T-shaped Y

belt clamp, then through the Y carriage, through the other Y belt clamp and into 2 M3

nuts.

2

Y-AXIS

Slide the Y carriage toward the Y motor. Slide the motor so that the pulley line up per-

fectly with the belt. After it is aligned tighten the Y Motor Holder. Then wrap the belt

around the pulley and pull it through towards the Y idler.

9

10

11

12

27

Slide the Y carriage towards the front of the printer towards the Y idler. Slide the Y

idler so that it aligns with the Y carriage. Tighten the Y idler securing it in place.

2

Y-AXIS

Insert 2 M3x25mm socket head screws with #6 washers (not shown) through the Y car-

riage, then through the Y carriage clamp, and into 2 M3 nuts. Pull the belt tight before

fully tightening the screws. Cut off any excess belt.

11

12

28

Place the Y Carriage spacers onto the Y carriage as shown. Line up all the holes. 2

Y-AXIS

Gently place the 9.75x 6 aluminum plate on the Y carriage spacers lining up the

holes. Then insert 6 M3x45mm socket head screws as shown and secure them with 6

M3 nuts.

13

14

15

16

29

Peal the backing off of the kapton heater. Carefully stick the kapton heater to the

bottom of the 9.75 x 11 aluminum plate as shown. (The side with the countersunk

holes is the top).

2

Y-AXIS

Carefully place 4 spacer over the 4 holes on the 9.75 x 6 aluminum plate. Then

secure the 9.75 x 11 aluminum plate using 4x M5x25mm flat head screws and 4x M5

thin nuts.

15

16

30

Step 2 Finished! Your printer should now look like this: 2

Y-AXIS

17

31

2

Y-AXIS

FRONT REAR

TOP BOTTOM

SIDES

32 UPPER FRAME

3

Step 3

ASSEMBLING THE

UPPER FRAME

33

Plastic Parts

Hardware

Prepare: 3

2x Upper Z

Vertex

4x Upper Vertex

Left & Right

2x Spool

Holder

1x Top X Brace 1x Top X Brace

w/Logo

1x Top Y Brace

UPPER FRAME

4x 340mm Extrusions 2x 420mm Extrusions (with holes)

60x M5x10 SH

4x M5x10 FH

4x M5x20 BH

4x M8x20 SH

4x 608ZZ Bearing

52x #10 Washer

56x M5 T-Slot Nut

4x M8 Nut

2x Z Rod Clamp

34

Attach an Upper Vertex to a 340mm extrusion using 1 M5x10mm SH screw

3

Insert 3 t-slot nuts each into the top and outer slots as shown below.

1

2

UPPER FRAME

35

Repeat steps 1-2 for the remaining 3 Upper Vertexs and 3 340mm extrusions. 3

Take 2 M5x10mm SH screw and 3 #10 washers and secure the upper vertex as shown.

Repeat for the other 3 diagonal extrusions.

3

4

UPPER FRAME

36

Screw an M5x20mm button head screw into the top of the 340mm diagonal extrusions

completed in the last step. DO NOT screw it in all the way. Leave it sticking up 5-10mm

as shown.

3

Repeat step 5 for the 3 other diagonal extrusions.

5

6

UPPER FRAME

37

Attach the diagonal extrusions to the Y-base completed in step 2 using 1 M5x10mm

flat head screw in the front where the plastic is countersunk. Attach an M5x10mm SH

screw and #10 washer on the other side.

3

Repeat step 7 for the 3 remaining 340mm diagonal extrusions.. Your Mendelmax 1.5

should now look like this:

7

8

UPPER FRAME

38

Take a 420mm extrusion (with drilled holes) and slide it so that the M5x20mm button

head screw slides into the bottom channel. Make sure the holes are parallel to the

diagonal extrusions. Continue sliding the extrusion through the next M5x20mm button

head screw.

3

Line up the holes that are in the 420mm extrusion so that you can clearly see the top

of the M5x20mm button head screws. Use an allen key to tighten the M5x20mm

button head screw all the way down.

9

10

UPPER FRAME

39

Repeat steps 9-10 using the last 420mm extrusion. Your Mendelmax 1.5 should now

look like this:

3

Prepare both Upper Z Vertex's prior to installation. Insert 2 M5 thin nuts as shown.

Due to overhang and other reasons the nut traps might be too small. If this is the case

take a drill bit or dremel and enlarge the hole enough so that the 2 M5 thin nuts will

fit.

11

12

UPPER FRAME

40

Loosely attach a Z Rod Clamp to the Upper Z Vertex using 2 M5x10mm SH screws as

shown. Repeat for the other Upper Z Vertex.

3

Looking at the top of your printer from the side, insert 20 t-slot nuts as shown.

13

14

UPPER FRAME

41

Attach the Upper Z Vertex using 4 M5x10mm SH screws and #10 washers. Leave it

hanging over the edge about 5mm.

3

Finish securing the Upper Z Vertex with 2 M5x10mm SH screws and #10 washers

through the bottom.

15

16

UPPER FRAME

42

Repeat step 16 for the opposite side. 3

Looking at the top of your printer from the side, insert 8 t-slot nuts as shown.

17

18

UPPER FRAME

43

Secure a Y Brace as shown using 4 M5x10mm SH screws and 4 #10 washers. Repeat for

the opposite side.

3

Attach 4 X Braces (one with a Mendelmax logo) using 16 M5x10mm SH screws and #10

washers.

19

20

UPPER FRAME

44

Take a spool holder and insert 2 M8x20mm SH screws through 2 608ZZ bearings and

close it off with 2 M8 nuts.

3

Repeat step 21 for the other Spool Holder.

21

22

UPPER FRAME

45

Attach the spool holder to the top of the printer using 2 M5x10mm SH screws. 3

Repeat step 23 for the remaining Spool Holder. Adjust the distance between each

spool holder to match the width of your filament spool.

23

24

UPPER FRAME

46

Step 3 is finished! Your Mendelmax 1.5 should now look like this: 3 25

UPPER FRAME

47

3

UPPER FRAME

FRONT REAR

TOP SIDE

48 Z-AXIS

4

Step 4

ASSEMBLING THE

Z-AXIS

49

Plastic Parts

Hardware

Prepare: 4

2x (4 Total) Z

Motor Support

2x Z Motor

Mount

2x Z Rod Clamp

1x X-end Idler 1x X-end Motor

8x M3x10 SH

4x M3x20 SH

16x M5x10 SH

8x #6 Washer

12x #10 Washer

4x M3 Nut

8x M5 Nut

4x LM10UU Bearing

Z-AXIS

2x 10mm Smooth

rod

2x Flexible Coupling

Leadscrew Hardware

2x NEMA 17

Motor

2x 1/4

Leadscrew

50

Prepare the Z Motor Mount prior to installation. Insert 4 M5 thin nuts as shown. Due

to overhang and other reasons the nut traps might be too small. If this is the case take

a drill bit or dremel and enlarge the holes enough so that the 4 M5 thin nuts will fit.

4

Loosely attach a Z Rod Clamp to the Lower Z Motor Mount using 2 M5x10mm SH

screws as shown. (Use M5x12mm SH screws if necessary)

1

2

Z-AXIS

51

Attach a left and right Z Motor Support to the Lower Z Motor Mount using 2

M5x10mm SH screws and 2 #10 washers. If the supports do not fit perfectly use a ra-

zor to enlarge the inset a little.

4

Repeat steps 1-3 for the other Lower Z Motor Mount.

3

4

Z-AXIS

52

Slide 2 LM10UU linear bearings into the X-end Motor & X-end Idler. Secure them using

4 M3x20mm SH screws and 4 M3 nuts.

4

Thread a leadscrew nut onto one of the 1/4 ACME leadscrews about half the length of

the spring.

5

6

Z-AXIS

53

Insert a leadscrew nut into the nut trap on the bottom of the x-end. 4

While holding the nut in place, insert the ACME leadscrew and spring as shown. Push

down on the leadscrew engaging the spring until you reach the bottom nut. Keep turn-

ing the leadscrew until it catches the bottom nut and threads into it.

7

8

Z-AXIS

54

Keep on rotating the leadscrew so that the x-end is positioned higher on the lead-

screw.

4

Repeat steps 6-9 for the other X-end. Both X-ends should now look as shown.

9

10

Z-AXIS

55

Attach the Lower Z Motor Mount & Supports to the side of your printer using 4

M5x10mm SH screws and 4 #10 washers.

4

Take a NEMA 17 motor and attach it to the Lower Z Motor Mount using 4 M3x10mm

SH screws and 4 #6 washers.

11

12

Z-AXIS

56

Attach a flexible coupling to the NEMA 17 motor shaft using the set screws that are in

the couplings. Position the coupling so that the top of the shaft is lined up where the

spiral starts. Also, make sure one of the set screws is lined up with the flat on the

motor shaft.

4

Take the X-end Idler & leadscrew assembly completed in step 10 and attach the 1/4

ACME leadscrew to the coupling as shown. Align the leadscrew to the top of the spiral

so that the ACME leadscrew and motor shaft do not touch.

13

14

Z-AXIS

57

While holding the X-end Idler & leadscrew, insert a 10mm smooth rod through the top

Z Rod Clamp. Slide it through the 2 LM10UU linear bearings inside the X-end Idler and

then into the bottom Z Rod Clamp. Tighten the 4 M5x10mm SH screws in the top and

bottom Z Rod Clamps securing the 10mm smooth rod.

4

Repeat steps 13-15 for the X-end Motor. Looking at the front of the printer, make sure

the X-end Motor is to the left and the X-end Idler is to the right.

15

16

Z-AXIS

58

4 Step 4 is Finished! Your Mendelmax 1.5 should now look like this: 17

Z-AXIS

59

4

FRONT REAR

TOP SIDE

Z-AXIS

60 X-AXIS

5

Step 5

ASSEMBLING THE

X-AXIS

61

Plastic Parts

Hardware

Prepare: 5

1x X Carriage

2x M3x6 Set Screw

7x M3x10 SH

4x M3x20 SH

1x M8x20 SH

3x Zip Tie

8x #6 Washer

2x 8mm Washer

1x Fender Washer

8x M3 Nut

1x M8 Nut

X-AXIS

2x 8mm Smooth

rod

2x 608ZZ Bearing

1x GT2 20t Pulley

1x 1164mm GT2 Belt

1x NEMA 17

Motor

2x GT2 Belt

Clamp

62

Attach a GT2 pulley using 2 M3x6mm set screws as shown. Make sure the pulley does

not touch the NEMA 17 motor.

5

Attach the NEMA 17 motor to the X-end Motor plastic part using 3 M3x10mm SH

screws.

1

2

X-AXIS

63

Install the idler into the X-end Idler plastic part in the following order: M8x30mm SH

screw, M8 fender washer, M8 washer, 2 608ZZ bearings, M8 washer, X-end Idler plas-

tic part, M8 nut.

5

Your idler should now look like this:

3

4

X-AXIS

64

Place 3 LM8UU linear bearings into the bottom of the X-carriage. Secure them using 3

Zip-ties. (not shown below) Visit our gallery to see more pictures of how the zip-ties

secure the linear bearings.

5

Slide in 2 8mm smooth rods through the X-end Motor side. Pass them through the

LM8UU linear bearings in the X-carriage and then into the X-end Idler. If the holes are

too small, carefully drill them out using either an 8mm or 5/16 drill bit.

5

6

X-AXIS

65

Secure the 8mm smooth rods using 2 M3x20mm SH screws and 2 M3 nuts. 5

Repeat step 7 for the X-end motor side.

7

8

X-AXIS

66

Take a GT2 belt and prepare to secure it to the X-carriage closest to the X-end Motor.

Face the teeth upwards. Secure the GT2 belt using an X Belt Clamp, 2 M3x10mm SH

screws, 2 #6 washers and 2 M3 nuts.

5

Wrap the belt around the pulley on the motor and towards the idler.

9

10

X-AXIS

67

Wrap the belt over the top of the idler and around the 608ZZ bearing and out the

bottom towards the X-carriage.

5

Loosely attach an X Belt Clamp using 2 M3x10mm SH screws, 2 #6 washers and 2 M3

nuts. Then pull the belt tight and tighten the 2 M3 screws.

11

12

X-AXIS

68

5 Step 5 is finished! Your Mendelmax 1.5 should now look like this: 13

X-AXIS

69

5

FRONT REAR

TOP SIDE

X-AXIS

70 EXTRUDER

6

Step 6

ASSEMBLING THE

EXTRUDER

71

Plastic Parts

Hardware

Prepare: 6

1x Extruder

Idler

1x Extruder

1x Extruder

Small Gear

1x Extruder

Large Gear

1x NEMA 17

Motor

EXTRUDER

1x J-Head

Hotend

1x M3x6 Set Screw

3x M3x12 SH

2x M3x50 SH

2x M4x20 SH

1x M8x20 Rod

4x M8 Washer

3x M3 Nut

2x M4 Nut

1x Hobbed Bolt

2x 608ZZ Bearing

2x Springs

1x Plastic Washer

72

Start step 6 by preparing the extruder. Pull off the support material around the hinge. 6

Insert a 608ZZ bearing with a M8x20mm stud passing through it, into the Extruder

Idler. It will be a tight fit so take pliers and squeeze the stud into place. Take turns

pressing in each side of the stud until it is firmly in place. Make sure the 608ZZ bearing

is free to spin.

1

2

EXTRUDER

73

Line the Extruder Idler up with the hinge on the Extruder. Thread in a M3x25mm SH

screw.

6

Drill out the plastic membrane that is blocking access to the motor holes. Then loosely

attach a NEMA 17 motor using 3 M3x12mm SH screws.

3

4

EXTRUDER

74

Drill out the plastic membrane where the hobbed bolt goes using an 8mm or 5/16

drill bit.

6

Press in a 608ZZ bearing as shown. If it is a tight fit use pliers to press it into place.

5

6

EXTRUDER

75

Insert an M3 nut into the Small Extruder Gear. If necessary use a small drill bit to ex-

pand the nut trap until the nut will fit.

6

Loosely attach the Small Extruder Gear to the motor shaft using a M3x6mm set screw.

7

8

EXTRUDER

76

Insert the hobbed bolt and 608ZZ bearing as shown. Make sure the hobb in the

hobbed bolt is lined up with the filament hole. If not, use a plastic washer in between

the Extruder and 608ZZ bearing. For more pictures visit our gallery.

6

Insert 4 M8 washers on the other end of the hobbed bolt.

9

10

EXTRUDER

77

Insert the Large Extruder Gear onto the hobbed bolt. Press it against the M8 washer

while interlocking it with the Small Extruder Gear. Once the Small Extruder gear is

aligned, tighten the M3x6mm set screw. Make sure the set screw is lined up with the

flat on the motor shaft. Now push the motor and Small Extruder Gear up against the

Large Extruder Gear and then tighten the M3x12mm SH screws.

6

Screw on an M8 nut until it is seated inside the Large Extruder Gear. DO NOT tighten.

Make sure the Large Extruder Gear is up against the M8 washers but DO NOT tighten

it.

11

12

EXTRUDER

78

Screw on the M8 thin nut up against the M8 nut inside the Large Extruder Gear. Using

a wrench, tighten the M8 thin nut while holding the Large Extruder Gear.

6

Press the assembled J-head into the recess on the bottom of the Extruder. Secure with

2 M3x25mm SH screws. Do not drill out the holes. The M3x25mm SH screws will

thread right into the extruder holding the J-head hotend in place.

13

14

EXTRUDER

79

Insert 2 M3 nuts into the nut traps on the top of the Extruder. 6

Insert filament into the filament path.

15

16

EXTRUDER

80

Flip the Extruder Idler up so that the filament is lined up with the filament guide.

Secure the Extruder Idler with 2 M3x50mm SH screws, 2 springs and 2 #6 washers.

Tighten the springs so they are about 75% compressed. (Spring tension will need to be

adjusted depending on filament.)

6

Insert 2 M4 nuts into the nut traps as shown.

17

18

EXTRUDER

81

Place the Extruder assembly onto the top of the X-Carriage as shown. Take note that it

goes on at an angle as shown. That way the motor does not rub up against the belt.

6

Secure the Extruder onto the X-Carriage using 2 M4x20mm SH screws.

19

20

EXTRUDER

82

6 Step 6 is finished! Your Mendelmax 1.5 should now look like this: 21

EXTRUDER

83

6

FRONT REAR

TOP SIDE

EXTRUDER

84 ENDSTOPS

7

Step 7

ENDSTOPS

85

Plastic Parts

Hardware

Prepare: 7

3x Micro Switch

ENDSTOPS

3x Endstop

Holder

2 8mm

1 10mm

6x M2.5x16 SH

3x M3x20 SH

6x M2.5 Nut

3x M3 Nut

86

Attach a Micro Switch to the Endstop Holder using 2x M2.5x16mm SH screws and 2x

M2.5 nuts.

7

Repeat step 1 for the remaining parts. You should now have 3 endstops ready to

Install.

1

2

ENDSTOPS

87

Install the X endstop holder (8mm) using a M3x20mm SH screw and a M3 nut. 7

Repeat step 3 for the remaining endstops. Take note of their positions below. Make

sure to use the 10mm endstop holder on the Z axis.

3

4

ENDSTOPS

88

7 After your endstops are installed, this is where your home position will be. When you hit home and before each print, your printer will move to this position. Make sure the

endstops engage right before crashing on the X & Y axis. For the Z axis, take a sheet of

paper and place it in between the hotend nozzle and print surface. Lower the Z axis

until you feel friction when moving the paper back and forth. If the paper starts bunch-

ing up, its too low. After you get it to the correct height adjust the endstop so that it

engages right at that point.

21

ENDSTOPS

89

7

ENDSTOPS

90 RAMPS 1.4

8

Step 8

WIRING DIAGRAM

RAMPS 1.4

91

8

Connect the electronic components as shown below:

RAMPS 1.4