RepRap Prusa i3 Manuel
Prusa i3 – Build Manual
Table of Contents
Forward............................................................................................................................................................................... 4
1. Y-AXIS Frame...............................................................................................................................................................5
1.1 Y-AXIS Long Sections.................................................................................................................................................................5
1.2 Y-Axis ear Section (Motor)........................................................................................................................................................6
1.3 Y-Axis Front Section (Idler).........................................................................................................................................................8
1.4 Y-Axis Lower Frame Completed..................................................................................................................................................9
2. Z-AXIS Frame.............................................................................................................................................................10
2.1 Z-Axis Frame Mounting.............................................................................................................................................................10
2.2 Z-Axis Top/Bottom mounts (PLA)............................................................................................................................................12
2.3 Z-Axis Motors & End-stop.........................................................................................................................................................13
3. Build Plate & Heated Bed...........................................................................................................................................14
3.1 Build Plate Mounting..................................................................................................................................................................14
3.2 Y-axis belt...................................................................................................................................................................................15
3.3 Heated Bed Mounting.................................................................................................................................................................17
4. amps Mounting.........................................................................................................................................................18
4.1 amps mount..............................................................................................................................................................................18
4.2 amps Y & Z Wiring..................................................................................................................................................................20
5. X-AXIS + Z-AXIS ods.............................................................................................................................................23
5.1 X-Axis Assembly........................................................................................................................................................................23
5.2 X-Axis Mounting........................................................................................................................................................................27
6. Extruder & Hot-End...................................................................................................................................................32
6.1 Hot-end Mounting .....................................................................................................................................................................32
7. X & Z-Endstop Triggers.............................................................................................................................................38
7.1 X-Endstop Trigger......................................................................................................................................................................38
7.2 Z-Endstop Trigger.......................................................................................................................................................................39
8. Final AMPS Wiring..................................................................................................................................................40
8.1 Heated Bed Connecting..............................................................................................................................................................41
8.2 Build Plate Fans Connecting......................................................................................................................................................41
8.3 Hot-End Connecting...................................................................................................................................................................41
8.4 Power Supply / Hot-End Fan and AMPS Fan Connecting.....................................................................................................42
9. Spool Mount................................................................................................................................................................ 44
9.1 Spool Mount Assembly..............................................................................................................................................................44
10. LCD / LCD Case & Mount........................................................................................................................................45
10.1 LCD Case Assembly.................................................................................................................................................................45
10.2 LCD Wiring .............................................................................................................................................................................46
11. First Power-on and Test.............................................................................................................................................47
11.1 First Power-on...........................................................................................................................................................................48
11.2 Motor Tuning (For reference, should not be required).............................................................................................................49
11.3 Filament Feeding......................................................................................................................................................................50
11.4 Extruder Calibration (Optional)................................................................................................................................................52
11.5 End-stop Test.............................................................................................................................................................................52
11.6 Bed Levelling Preparation........................................................................................................................................................53
11.7 Bed Levelling............................................................................................................................................................................54
11.8 First Print..................................................................................................................................................................................55
Appendix A – Motor Wiring.............................................................................................................................................57
Appendix B – Idler Pulleys...............................................................................................................................................63
Appendix C – Power Supply Wiring................................................................................................................................66
Appendix D – Firmware Update .....................................................................................................................................68
Appendix Z – Troubleshooting.........................................................................................................................................69
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Prusa i3 – Build Manual
Kit Parts :
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Prusa i3 – Build Manual
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Prusa i3 – Build Manual
Forward
This manual is intended as a guide to your EP AP Prusa I3 build, it would be impossible to cover everything
involved in building and tuning a EP AP Prusa I3 in a single 80 page guide, but it will greatly smooth the
way to getting you up and running quickly. You are strongly encouraged to consult some on the many other I3
resources online especially the AMPS 1.4 wiki (http://www.reprap.org/wiki/ AMPS_1.4) and other online
Prusa I3 build manuals such as (http://reprap.org/wiki/Prusa_i3_Build_Manual). This is especially true when
you come to tuning your printer during your first prints. Above all, you can build a EP AP quickly but never
build one rushed. Every nut and bolt thats perfectly tensioned, every rod that's perfectly aligned (especially the
base), every bearing that's perfectly seated .. they will all translate to better print quality. The electronics are
doubly important, check and triple check every connection is correct,tight and secure before powering up to
avoid costly and time consuming mistakes!
Safety Notes:
High Current : Building and Operating a EP AP involves high current, especially for the heated bed
which can draw 10A on its own. All cables should be securely connected and checked. All high current
connections should be well insulated to avoid contact and well secured to prevent movement at the points
of connection.
High Temp : A EP AP hot-end can reach well in excess of 200c , caution is advised during operation.
High Forces : A EP AP motor can exert considerable force, caution is advised putting your hands near
any of the axis while in operation
Fire isk : An operating EP AP is a non-negligible fire risk. Don't ever leave one running un-
attended. It would be advisable to have an electrical fire extinguisher on hand while operating a
EP AP. All of the high current and high temperature electronics are operating while influenced by
vibration and movement, so even well secured and tightened electrical connections can work loose over
time. If for example your heated-bed connection worked loose at the AMPS it can spark and burn the
plastic housing. A worse example would be your hot-end thermistor working loose, causing a runaway
hot-end temperature which would only stop heating (>500c) after burning through the electrical
connection. You should regularly check your electrical connections for signs of working loose or
excessive heat (especially around the high current AMPS connections). Your AMPS fan should also
be checked that it is putting sufficient airflow on these connections.
Hot-End Maintenance : Your MK8 hot-end (in fact any hot-end) is a high maintenance component, to
keep it running safely and producing high quality prints it should be regularly checked and serviced.
You will need to learn to strip down, clean and re-assemble your MK8 with a new barrel/nozzle which
should be done as a rough guide between 1 or 2 kilos of PLA. Here we completely service our hot-ends
after every single kilo reel of PLA to keep print quality high as towards the end of a second kilo reel you
will see print quality visibly degrade. Apart from print quality, safety is also a big factor as the hot-end is
the biggest fire risk on your EP AP if run un-checked and un-serviced.
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Prusa i3 – Build Manual
1. Y-AXIS Frame
1.1 Y-AXIS Long Sections
First take the two 350mm M8 smooth rods and slot one LM8UU bearing onto one, and two LM8UU bearings
onto the other. Next slot the four Y-Corners onto the ends of the 380mm M10 Threaded ods, then slot the two
350mm M8 Smooth ods (with bearings) into the Y-Corner top slots, finally screw on and loosely hand tighten
the M10 nuts (and washers). The smooth rods need to be pushed well into the end corner slots .. but its not absolutely
essential they are flush with the back of the slot, they aren't going to move around once its all assembled.
Fig 1.1 (Y-Axis Long Sections) :
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Prusa i3 – Build Manual
1.2 Y-Axis Rear Section (Motor)
Fig 1.2 Parts:
Firstly wire up a round shaft motor with about a 10cm extension length of wire & dupont connector. (see appendix A,
motor wiring). Next slot the GT2 timing pulley onto the motor shaft with the teeth close to the motor and gently tighten
the grub screws (see Fig 1.2a). Next mount the endstop into the endstop mount (it will only fit in one way round) and
secure with 2 16mm M3 bolts+nuts (Fig 1.2a). Next mount the Motor onto the Y Endstop / Motor Mount using 3 x 16mm
M3 bolts with M3 washers. Make sure the wires from the motor are orientated at the back of the motor mount and the
motor is mounted on the right hand side of the mount (Fig 1.2a).
Fig 1.2a:
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Prusa i3 – Build Manual
Next mount the motor assembly onto the two M8 threaded rods with the GT2 timing pulley teeth in the centre
and the motor wires feeding out through the back of the two rods (Fig 1.2b). Just hand tighten the M8 nuts at
this stage.
Fig 1.2b:
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1.3 Y-Axis Front Section (Idler)
Secure the idler onto one of the M8 threaded rods, dead center (loosely hand tighten) see Fig 1.3a If the idler pulley isn't
pre assembled see appendix B (idler pulleys).
Fig 1.3a
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1.4 Y-Axis Lo er Frame Completed
To complete the lower frame slot the completed end sections into the Y-corners of the completed long side
sections. Leave about 1 or 2 mm of M8 thread protruding and just loosely hand tighten the M8 nuts for now,
they will be adjusted later when the build plate is mounted (section 3). With the idler at the front (top M8
threaded rod) , motor at the back, single bearing on the left hand smooth rod and two bearings on the right hand
smooth rod (Fig 1.4a). The 30mm centre 'frame grip' washer on the M10 threaded rod should be 10cm with a MK8
extruder (or 11cm with a J-Head/Gregs Wade Extruder) from the flat inner of the rear Y-corner (Fig 1.4b).
Fig 1.4a:
Fig 1.4b:
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Prusa i3 – Build Manual
2. Z-AXIS Frame
Fig 2.0 parts:
2.1 Z-Axis Frame Mounting
Secure the frame between the two large 30mm M10 washers, then hand tighten on each side leaving approx
10cm between the flat rear of the Y-Corner and the rear of the frame (Fig 2.1a).
Fig 2.1a:
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