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