trinity labs mendelmax 1.5+ build instructions

7/13/2019 Trinity Labs MendelMax 1.5+ Build Instructions

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T R I N I T Y L A B S M E N D E L M A X 1 . 5 + B U I L D I N S T R U C T I O N S


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CONTENTSINTRODUCTION ........................................................................................................................................... 4

Kit Specifics ................................................................................................................................................... 4Overview......................................................................................................................................................... 5

GETTING TO KNOW YOUR MENDELMAX ...................................................................................... 6

Parts Overview .............................................................................................................................................. 6

PREPPING THE PARTS ............................................................................................................................. 15

Whats Needed? ........................................................................................................................................... 15

Tools: ........................................................................................................................................................ 15

Hardware: ................................................................................................................................................. 15

Steps: ............................................................................................................................................................. 16

LOWER FRAME ASSEMBLY .................................................................................................................... 18

Whats Needed? ........................................................................................................................................... 18

Tools: ........................................................................................................................................................ 18

Hardware: ................................................................................................................................................. 18

Plastics: ..................................................................................................................................................... 18

Steps: ............................................................................................................................................................. 19

Y-AXIS ASSEMBLY ...................................................................................................................................... 29

Whats Needed? ........................................................................................................................................... 29

Tools: ........................................................................................................................................................ 29

Hardware: ................................................................................................................................................. 29

Plastics: ..................................................................................................................................................... 29

Steps: ............................................................................................................................................................. 30

UPPER FRAME ASSEMBLY ...................................................................................................................... 45

Whats Needed? ........................................................................................................................................... 45

Tools: ........................................................................................................................................................ 45

Hardware: ................................................................................................................................................. 45

Plastics: ..................................................................................................................................................... 45

Steps: ............................................................................................................................................................. 46

EXTRUDER ASSEMBLY ............................................................................................................................ 54

Whats Needed? ........................................................................................................................................... 54

Tools: ........................................................................................................................................................ 54

Hardware: ................................................................................................................................................. 54


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Plastics: ..................................................................................................................................................... 54

Notice: ...................................................................................................................................................... 54

Steps: ............................................................................................................................................................. 55

X-AXIS ASSEMBLY ...................................................................................................................................... 63

Whats Needed? ........................................................................................................................................... 63

Tools: ........................................................................................................................................................ 63

Hardware: ................................................................................................................................................. 63

Plastics: ..................................................................................................................................................... 63

Steps: ............................................................................................................................................................. 64

Z-AXIS ASSEMBLY ...................................................................................................................................... 69

Whats Needed? ........................................................................................................................................... 69

Tools: ........................................................................................................................................................ 69

Hardware: ................................................................................................................................................. 69Plastics: ..................................................................................................................................................... 69

Steps: ............................................................................................................................................................. 70


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INTRODUCTION

Kit Specifics

Like every other RepRap kit, the MendelMax consists of customized pieces of hardware that the builder chooses.

The kit described in this log consists of the following components:

Trinity Labs MendelMax 1.5+ Hardware Kit, with upgraded Linear Y-Axis Rail Kit andExtruder Hardware

Techpaladin plastics, for use with the MM1.5 Hardware Kit: 8 & 10mm Precision ChromedRods, Precision Leadscrews with Delrin Nuts, as well as a Jonas Skuehling/Greg/WadesExtruder

Lulzbot Budaschnozzle 1.1 Arduino Mega 2560, RAMPS 1.4 kit with Pololu 4988 Stepper Drivers 110V Power Supply 110V Silicone Heated Bed

I will be including the X-Carriage instructions that I used to build my kit, the carriage included withthe TrinityLabs kit is a variation of the Supaflat X-Carriage by AlephObjects.

Section

1


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INTRODUCTION

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Overview

Since not everyone that would like a 3D printer knows what a hobbed bolt is, or a socket head capscrew, there will be a section outlining all of the parts that were included in the kit.

After the component breakdown, the manual will be split up into sections that will build upon theprevious, but separate the components that are not part of the regular MendelMax kit.

The sections are as follows:

Prepping Parts Lower Frame Y-Axis Upper Frame X-Axis Z-Axis Electronics Calibration

Each section will list the hardware, plastics and tools needed to build that sections assembly.

PLEASE NOTE: Due to the fact that the community requires this documentation ASAP, I will notbe including the Electronics nor Calibration sections in the initial release. I will follow up with asecond revision that includes these sections.


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GETTING TO KNOW YOUR

MENDELMAX

Parts Overview

MM Hardware Bag M3 Nuts x10 M3 Washers x30 M3 SHCS x30 T-Slot Nuts x100 M5x10mm SHCS x120 M5 Thin Nuts x100 M5 Washers x100 M5x12mm BHS x4 M5x12mm SHCS x18 M5x20mm SHCS x8 M5x10mm FHS x4 M8x30mm SHCS x2 M8 Nuts x2 M8 Washers x5

Linear Bushings8mm x8 Linear Bushings10mm x4 608ZZ Bearings x8 Z Shaft Couplers M5M6.35 x2 GT2 Pulleys x2

Y-Axis Rail Hardware M3x10mm SHCS x8 M3 Nyloc Nuts x8 M5x10mm x7 M5x16mm x4

M5 Thin Nuts x4 M5 Washers x11 M6x10mm SHCS x4 Table Corners x4 Rail Belt Clamp x1

Y-Axis Mounting Hardware

Corner x4 T-Slot Nuts x8 M5x10mm x8 M5 Washers x8

Y-Axis Rail Kit Insulator Plate x1 Rail & Car Assy x1 Borosilicate Glass x1 PTFE Sheets x2

Frame Kit 300mm Extrusions x4 340mm Extrusions x4 420mm Extrusions x7

Heated Bed Kit Heated Bed x1 SSR x1 M5x65mm SHCS x4 M5 Nuts x4 M4 Nyloc x2 M3 Nyloc x2 M3x12mm FHS x2 Power Jack x1 Fuses x2

Thermistor Kit Thermistor x1 Connector Wire x1 Grey Wire x1 PTFE 30Gauge Tube x2 1/8 Heat shrink 1/16 Heat Shrink

Section

2


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GETTING TO KNOW YOUR MENDELMAX

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Linear Kit Precision Chromed Rods10mm x2 Precision Chromed Rods8mm x2 Precision Leadscrews x2

Delrin Nuts x2

Electronics Kit RAMPS 1.4 x1 Arduino 2560 Mega x1 End Stops x3 LED Strips x2 Budaschnozzle 1.1 x1 Stepper Motors x5 110V Power Supply x1

Extruder Hardware Kit M8x25mm Stud x1 M8 Nut x2 M8 Washer x4 M4x55mm x4 M4 Nut x4 M4 Washer x15 M3x10mm x4 M3x25mm x2 M3 Washer x10 M3 Set Screw x2

Hobbed Bolt x1 608ZZ Bearing x3

Plastics Kit Top Vertex x4 Bottom Vertex - Upper Left x2 Bottom Vertex - Upper Right x2

Bottom Vertex - Lower Right x2 Bottom Vertex - Lower Left x2 70mm Jig x1 Y Motor Mount x1 Y Rod Clasp x4 Y Idler Mount x1 Y Idler Tensioner x1 X End Clamp x1 X End Motor Side x1 X End Idler Side x1 X Carriage for Self Aligning Bronze

Bushings x1 Lower Motor Mount for 10mm Rods

x2 Z- Top Vertex for 10mm Rods x2 Z- Lower Motor Mount Support (A)

x2 Z- Lower Motor Mount Support (B)

x2 Rod Clasp x4 Extruder Idler Holder x1 Extruder Small Gear x1

Extruder Large Gear x1 Groovemount Holder x1


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M3 Washer

M3x10mm SHCS

M5 Washer M5x10mm

M3 Nut

M5 Thin Nut

T-Slot Nut

M5x12mm SHCS

M5x12mm BHSM5x20mm SHCS

M5x10mm FHS

M8x30mm

M8 NutM8 Washer

608ZZ Bearing

420mm Aluminum

340mm Aluminum Extrusion300mm Aluminum Extrusion

Figure 1: Frame Components


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GT-2 BeltGT-2 Pulley

Precision Leadscrews

10mm Precision Chromed Rods8mm Precision Chromed Rods

8mm Bronze Bushing10mm Bronze Bushing

Delrin ACME Nut

Z-Shaft Coupler M5 to M6.35

Figure 2: Linear Components


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M5x10mm SHCS

Corner

T-Slot Nut

M5 Washer

M3-10

M3 Nyloc NutsM5x16mm SHCS

M5 Thin NutsM5 Washers

M6x10mm SHCSTable Corners

Rail Belt Clamp M5x10mm SHCS

Y-Axis Car

Y-Axis Rail

Heated Bed PlatePTFE Sheets

Borosilicate Glass

Insulator Plate

Figure 3 - Y-Axis Components


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M8x25mm Stud

M4 Nut

M8 Nut

Hobbed BoltM4x55mm

M3 Washer M4 WasherM8 Washer

608ZZ Bearing

M3x25mm

M3x10mm SHCS

M3 Set Screw

Figure 4 - Extruder Hardware


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Mechanical Endstop

Arduino Mega2560

RAMPS 1.4Lulzbot Budaschnozzle 1.1

Solid State Relay (SSR)Power Jack

M5x65mm SHCS

FuseM3x12mm FHSM3 Nyloc Nut

M4 Nyloc

M5 Nut

NEMA 17 Stepper Motor

110v Power Supply

Figure 5 - Electronic Components


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Figure 8 - X-Axis Plastics

Figure 6 - Frame Plastics

Figure 7 - Y-Axis Plastics

Top Vertex x4 Bottom Vertex -Upper Left x2

Bottom Vertex -

Lower Left x2

Bottom Vertex -

Lower Right x2 70mm Jig Bottom Vertex -Upper Right x2

X-End Clamp X-Carriage - For

Self-Aligning Bronze

BushingsX-End -

Idler SideX-End -Motor Side

Y-Axis Motor Mount Y-Idler TensionerY-Idler Mount


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Figure 9 - Z-Axis Plastics

Figure 10 - Extruder Plastics

Lower Motor Mount

For 10mm Rods x2

Top Vertex For

10mm Rods x2

Lower Motor Mount

Support (A) x2

Rod Clasp x4

Lower Motor Mount

Support (B) x2

Idler Holder Large GearGroovemount HolderSmall Gear


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PREPPING THE PARTS

Whats Needed?

Tools:

File Sandpaper

Misc Drill Bits for Reaming M5 Tap 6mm or Drill Bit DrillHardware:

300mm Extrusion x4 340mm Extrusion x4 420mm Extrusion x2 Plastics

Section

3


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PREPPING THE PARTS

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Steps:

1. Look over all of the plastic parts to see if there are any pieces of plastic stuck inside holes, orif the holes themselves are not clean.

2. Use a drill bit that is the size of the hole that you want to clean and push it into the hole toloosen and remove any plastic bits.

3. Check the outside of the plastic to see if there are any pieces of filament that are loose oroverhanging and remove them with the sandpaper and/or file.

4. While you are inserting nuts into nut traps, if they are not easily slid in, then first check tomake sure you have the correct size nut. Second, use a file or knife to widen the slot a bit, inorder for the nut to fit snug inside.

5. Gather up the 340mm and 300mm extrusions. I found that bundling them together withtape makes it easier to tap the holes in the ends.

6. Tap all 8 of the extrusions, both ends, and make sure that any debris is blown out of theholes.

7. Gather two 420mm Extrusions and the 70mm Jig.8. Line the jig up to the end of one extrusion and using your drill, proceed to drill a hole

through the extrusion.


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PREPPING THE PARTS

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9. Remove the debris and repeat on the other side.

10.Repeat with the other extrusion.


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LOWER FRAME ASSEMBLY

Whats Needed?

Tools:

4mm Hex KeyHardware:

M5x10mm Socket Head Cap Screws M5 Washers M5 Thin Nuts T-Slot Nuts 300mm Extrusion x4 420mm Extrusion x4 (Non Drilled)Plastics:

Bottom Vertex - Lower x4

Section

4


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Steps:

1. Locate a 300mm Extrusion and place a T-Slot Nut in one of the slots.

2. Get one of the Bottom Vertex - Lower Right pieces and secure into the 300mm Extrusionwith 2 - M5x10mm SHCS and 2 - M5 Washers.


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3. Place 3 - T-Slot Nuts into the other end of the extrusion, in the same slot.

4. Locate one of the Bottom VertexLower Left pieces and secure into the other side of the300mm Extrusion with 2 - M5x10mm SHCS and 2 - M5 Washers.


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5. Locate another 300mm Extrusion and repeat the same procedure

6. Use only 3 - T-Slot Nuts in total, not 4 as above.

NOTE: Use only 3 T-Slot Nuts


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7. Secure with a total of 4 - M5x10mm SHCS and 4 - M5 Washers.

8. To localize during the rest of the build, the extrusion with the 4 - T-Slot Nuts will be the

front of the printer, while the other 300mm Extrusion with 3 - T-Slot Nuts, is the rear.

9. Locate one of the 420mm extrusions and place 4 - T-Slot Nuts into it.


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10.Arrange the front and rear extrusion assemblies to line up with the 420mm extrusion.

11.Secure with 2 - M5x10mm SHCS and 2 - M5 Washers.12.Repeat for the other side.


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13.Locate another 300mm extrusion and place 2 - T-Slot Nuts inside the side slot, 2 in theopposite side and 2 in the top slot.

14.Position this extrusion above the front extrusion and secure with 4 - M5x10mm SHCS and 4M5 Washers.

T-Slot Nut Locations 2 per)


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15.Locate the last 300mm Extrusion and place 3 - T-Slot Nuts into the side slot, 2 in theopposite side slot, and 2 in the top slot.

Note the locations of the T-Slot Nuts


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16.Position the extrusion above the rear extrusion and secure with 4 - M5x10mm SHCS, and 4 -M5 Washers.

Reverse View


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17.Gather a 420mm Extrusion and place 4 - T-Slot Nuts in the side slot, and 2 - T-Slot Nuts inthe top slot.

18.Locate the extrusion above one of the side extrusions, and secure with 2 - M5x10mm SHCS,and 2 - M5 Washers.

Note the locations of the T-Slot Nuts


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19.Repeat for the other side.

20.Lower Frame Assembly Complete, continue onto the Y-Axis Assembly.


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Y-AXIS ASSEMBLY

Whats Needed?

Tools:

2.5mm Hex Key 4mm Hex Key 6mm Hex Key

Hex Key

Ruler/Measuring TapeHardware:

Y-Axis Rail Hardware Y-Axis Mounting Hardware Y-Axis Rail and Car Assembly Borosilicate Glass Plate

G-10 Insulator Plate Heated BedPlastics:

Y-Axis Motor Mount x1 Y-Axis Idler Mount x1 Y-Axis Idler Tensioner x1 Y-Axis Rail Belt Clamp x1 Y-Axis Bed Corner Pieces x4

Section

5


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Y-AXIS ASSEMBLY

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Steps:

1. Locate a 420mm Extrusion and place 7 - T-Slot Nuts in the top slot, 2 in a side slot, and 2more in the other side slot.

Note the slot locations for the T-Slot Nuts


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Y-AXIS ASSEMBLY

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2. Locate the Corner Brackets from the Y-Axis Mounting Kit and attach them to the four sidesof the extrusion using the included 4 - M5x10mm SHCS and the installed T-Slot Nuts.

3. Position the extrusion in the center of the printer between the other 420mm Extrusions,lining up the T-Slot Nuts (not shown) with the bracket holes.


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Y-AXIS ASSEMBLY

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4. Attach the extrusion with 4 - M5x10mm SHCS and 4 - M5 Washers, do not tighten all of theway.

5. Using a ruler or tape measure, ensure the extrusion is in the center of the printer betweenthe 420mm extrusions. With a standard MendelMax, this would be 130mm.

6. Tighten the screws and double check the center measurement.


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Y-AXIS ASSEMBLY

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7. Using the Y-Axis Rail as a guide, position the T-Slot Nuts in the extrusion so that they willbe under the holes in the rail.

8. Position the Y-Axis Rail over the extrusion, ensuring that it is in the center of the printer,between the 300mm Extrusions.


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Y-AXIS ASSEMBLY

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9. Secure with 7 - M5x10mm SHCS and 7 - M5 Washers, but do not tighten all the way.

10.Check the distance, making sure that the Y-Axis Rail is in the center of the printer, between

the 300mm Extrusions, then tighten the screws.


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Y-AXIS ASSEMBLY

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11.Locate the Y-Axis Rail Car and the Insulator Plate. Please Note that the later kits willinclude M6 Button Head Screws for the next step.

12.Position the Y-Axis Rail Car under the Insulator Plate and using the 4 - M6x10mm SHCS,attach the Insulator Plate to the Y-Axis Rail Car. It might be a tight fit, so you might have to

turn each screw a little at a time to get them all of the way in.

13.Gather the Corner Pieces, 4 - M5x16mm SHCS, 4 - M5 washers and 4 - M5 Nuts. These willbe used to attach the Corner Pieces to the Insulator Plate. Note that the Corner Pieces havea nut trap at the top of them to hold a nut securely while one can turn the screw underneath.


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Y-AXIS ASSEMBLY

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14.Check to see if the M5 Nuts are tight inside the nut traps, if any of them are, line the nut upwith the hole in the corner piece and screw the M5x16mm SHCS from the bottom into the

nut and let it pull the nut into the trap. Remove the screw. Repeat this step for all of the

pieces that are tight.

15.Place a corner piece onto the insulator plate.

Fully seated


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Y-AXIS ASSEMBLY

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16.Gather 2 - M3x10mm SHCS and drop into the smaller holes to the side of the nut trap.

17.Gather 2 - M3 Nyloc Nuts and from the bottom, attach them to the M3 SHCS. Do nottighten. Note: The corner pieces need a little give in order to enable the bed leveling screws

the chance to move the glass without breaking it. Repeat for the rest of the corners.


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Y-AXIS ASSEMBLY

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18.Fit a M5 Washer over the M5x16mm SHCS and feed through the bottom of the plate upinto an M5 Nut in the nut trap.

19.Test the fit of the glass on the bed. It should be snug and not have any play. If it does, thenyou will need to remove the glass and adjust the corner pieces position.


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Y-AXIS ASSEMBLY

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20.Remove the glass from the bed and secure the Heater Element to the glass plate ensuringthat the surface is clean before doing so. Note: The wiring should be routed towards the

back of the frame when mounted on the Y-Axis.

21.Attach the Y-Axis Belt Clamp onto the Y-Axis Rail Car by flipping over the printer

assembly, positioning the belt clamp onto the car and using 4M3x10mm SHCS.

22.Gather the pieces to build the Y-Axis Tensioner Assembly: Y Idler Tensioner, Y Idler

Mount, 1 - M8x30mm, 2M8 Washers, 2608ZZ Bearings.


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Y-AXIS ASSEMBLY

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23.Build the Tensioner as per the photo.

Bolt Head

Bearings x2Washer

Washer

Nut


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Y-AXIS ASSEMBLY

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24.Attach the tensioner assembly to the mount by slipping 2M5 Nuts into the slots on thetensioner. Locate onto the mount, then fasten with 2M5x10mm SHCS and 2 - M5

Washers.

Nut Slots


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Y-AXIS ASSEMBLY

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25.Attach the assembly to the front of the frame with 2M5x10mm SHCS and 2M5Washers into the captured T-Slot Nuts.

26.Trap an M5 Nut in the assembly and secure with 1M5x10mm SHCS. This will serve as the

Y-Axis Tension Adjustment Screw.


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Y-AXIS ASSEMBLY

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27.Gather the Y Motor Mount, 2M5x10mm SHCS, and locate the mount on the rear of theframe. Secure using the hardware into the T-Slot Nuts that are trapped in the frame

extrusion. Note the orientation of the mount.

28.Attach one of the NEMA 17 Motors to the mount using 2 - M3x10mm SHCS, 2M3

Washers. Note: I routed the wires so they will go under the frame.


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Y-AXIS ASSEMBLY

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29.Locate the GT2 Pulley and secure it onto the motor shaft, ensuring that it is flush with thetip. Use the included 1/16 hex key.

30.Locate the GT2 belt and test route it. See PHOTO for routing.

31.Secure it with Zip Ties.

Start Here

Around the motor shaft

Around the IdlerEnd Here


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UPPER FRAME ASSEMBLY

Whats Needed?

Tools:

3mm Hex Key 4mm Hex Key T-20 Torx KeyHardware:

M5x10mm SHCS x28 M5 Washers x24 M5x10mm FHS x4 T-20 Self Tapping Blind Screws x4 T-Slot Nuts x24 340mm Extrusion x4 420mm Extrusion x2 (Drilled)Plastics:

Bottom VertexesUpper Left x2 Bottom Vertexes - Upper Right x2 Top Vertexes x4 Z- Top Vertex for 10mm Rods x2

Section

6


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Steps:

1. Gather the 340mm Extrusions, 2Bottom Vertex Upper Left and 2Bottom VertexUpper Right pieces, and 4M5x10mm SHCS.

2. Begin by placing a washer onto a SHCS and locating it into the hole on the one of thevertexes, see photo.

3. Tighten the screw all of the way.

Screw


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4. Repeat for all of the extrusions and vertexes.

5. Locate the other holes on the vertex. Now slide 2T-Slot Nuts, into the slots so that you

can secure the vertex through the other holes into the extrusion. See PHOTO.


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6. Repeat this for the rest of the assemblies. In total, you will need 8T-Slot Nuts, 8M5x10mm SHCS, and 8M5 Washers.

7. Attach one of the assemblies to the Lower Frame with 1M5-10mm FHS, and 1M5x10mm SHCS with 1M5 Washer. Note Do not tighten all of the way. Repeat for the

rest of the vertexes. Use a 3mm Hex Key for M3 FHS.


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8. Locate the 4Self Tapping Blind Screws and fasten them to the top end of the 340mmExtrusions. Use a T-20 Torx Key.

9. Trap 2T-Slot Nuts into each 340mm Extrusion before you mount the 420mm Extrusion

onto the ends using the blind screws. Note: Do not tighten.

Trap two T-Slot Nutsbefore sliding the top

extrusions on


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10.Trap 4T-Slot Nuts into the front slot of the front 420mm Extrusion, 4T-Slot Nuts intothe rear slot of the rear 420mm Extrusion, and if using the Optional Spool Holder that is

offered, then stick 2T-Slot Nuts into the tops of these extrusions as well.

11.Locate the 2 - Top Vertex for 10mm Rods. These will be installed on the 420mm Extrusionsusing 4M5x10mm SHCS and 4M5 Washers. Do not tighten.

T-Slot Nuts Locations are marked, visible locations inblue and unseen locations in green.


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12.Locate the 4Top Vertexes. Mount these on the corners of the 340mm and 420mmExtrusions using 8M5x10mm SHCS and 8M5 Washers per vertex. Do not tighten.

13.Tighten the M5x10mm FHS that are in the Lower Frame, such that the vertexes are as

square as possible.

Also, tighten the M5x10mm SHCS that is on the same vertex, again, making sure that

nothing goes out of square as you are tightening. Repeat for all of the Lower Vertexes.

SquareM5x10mm

SHCS


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14.Take a measurement at the top of these vertexes. It should be 260mm. Take a measurementat the bottom edge of the top vertexes. It should be 260mm, or at least match the above

measurement.

15.If it doesnt match, loosen the blind screws and adjust the 340mm extrusions back and forthuntil it does match.

16.Tighten the blind screws through the extrusion holes once everything is square.17.

Repeat steps 15-16 for the other side.

Adjust these extrusions


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18.Tighten the Upper Vertexes so that their edges are parallel with their respective extrusions.


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EXTRUDER ASSEMBLY

Whats Needed?

Tools:

4mm Hex Key 6mm Hex Key 2.5mm Hex Key 3mm Hex Key

Hex Key

Hardware:

Extruder Hardware Kit LulzBot Budaschnozzle 1.1Plastics:

Idler Holder x1

Small Gear x1 Large Gear x1 Groovemount Holder x1

Notice:

Not all extruder and hotend combinations are created nor assembled equal. The extruder that I amusing is ajonaskuehlingretake on Gregs/Wades Extruder. It can be found here:

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

My hotend is a Lulzbot Budaschnozzle 1.1 with 0.5mm tip.

The Extruder Hardware is the additional kit offered by TrinityLabs.

Section

7
http://www.thingiverse.com/thing:18379http://www.thingiverse.com/thing:18379http://www.thingiverse.com/thing:18379


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EXTRUDER ASSEMBLY

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Steps:

1. Locate the Extruder Plastic Parts and Hardware kit.2. Take the Extruder Groovemount piece and insert a 608ZZ Bearing into the cutouts.

3. Locate the Idler Holder, 1 - M8 Stud, and 608ZZ Bearing.4. Place the bearing over the stud and press inside the idler holder.


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EXTRUDER ASSEMBLY

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5. Attach the Idler Holder Assembly onto the Groovemount piece with 1 - M3x35mm SHCSand 1 - M3 Washer.


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EXTRUDER ASSEMBLY

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6. Locate the Hobbed Bolt. Depending on the location of the grooves on the bolt, you mightneed to pad it with washers when you insert it through the two bearings. As it turns out. Idid not have to. I have marked the location of where you might have to locate the washers inthe photo.

7. Of course, if the hobbing is past the hole to the right (closest to the head of the bolt)without any washers, the hobbed bolt will not work.

Look foralignment

here

adjust withwashers here


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EXTRUDER ASSEMBLY

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8. Place 2 - M8 Washers on the end of the bolt. These will be adjusted when the small gear isplaced on the motor.


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EXTRUDER ASSEMBLY

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9. Locate 1 - M8 Nut and secure it into the nut trap in the Large Gear. Place the gear on theend of the bolt. Tighten it up so that the bolt will spin with the bearings, but not loosen thenut and subsequently, the large gear. If this happens, tighten it more.

10.Place 2 - M4 Nuts into the nut traps on the top of the assembly.


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EXTRUDER ASSEMBLY

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11.Attach 2 - M4x55mm SHCS into the holes, through the nuts, deep enough to hold, but notall the way.

12.Attach the Small Gear onto a NEMA 17 Stepper Motor, leaving 2-3mm of space betweenthe housing and the bottom of the gear and ensuring that the flat of the shaft is facing thehole in the side of the gear.


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EXTRUDER ASSEMBLY

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13.Place a nut into the nut trap on the gear and secure it to the shaft, using 1 - M3 Set Screw.14.Attach the motor onto the main assembly so that the alignment of the gears can be checked

with 1 - M3x10mm SHCS.

15.Using 6 - M8 Washers between the large gear and the main assembly, align the gears.


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EXTRUDER ASSEMBLY

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16.Using 2 - M3x10mm SHCS, finish attaching the motor to the main assembly.

17.Check for proper gear meshing and if it is not correct, loosen the screws that hold the motorto the assembly, move the motor towards the gear, and tighten the screws back up.

Attach screwsmarked

Ensure propermeshing ofgearing


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X-AXIS ASSEMBLY

Whats Needed?

Tools:

4mm Hex KeyHardware:

M5x10mm SHCS x8 M5 Washers x8 M5 Thin Nuts x8 8mm Self Aligning Bronze Bushings x8 10mm Self Aligning Bronze Bushings x4 8mm Precision Chromed Shafts x2 10mm Precision Chromed Shafts x2 Delrin Leadscrew Nuts x2 Precision Leadscrews x2Plastics:

X-Carriage for Bronze Bushings X-End Motor Side for 10mm Shafts X-End Idler Side for 10mm Shafts X-End Motor Side Clamp

Section

8


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Steps:

1. Locate the X-Axis Carriage, and all of the 8mm and 10mm Self-Aligning Bronze Bushings.2. Using a suitably sized piece of rod, insert into the bushings and with a pair of pliers, or an

adjustable wrench, rock the bushing around until it is loose in its holder.

3. Repeat for all of the other bushings.4. Press the bushings into the carriage. (One is intentionally missing from the photo.)

5. Insert 1 - 8mm Precision Chromed Steel Rod and move the carriage back and forth until themovement is smooth. Remove the rod.

Move the rod so that it moves the bearing throughout its entire range of motion


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6. Repeat for the second 8mm rod. Note: In photo the carriage IS upside down.

7. Locate the X-Axis Motor End and Clamp. Trap 2 - M5 Nuts into the bottom of the motor

end and secure with 2 - M5x10mm SHCS. (Screws are not inserted in the photo)

Arrows show where screws go


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8. Insert both rods, and secure the clamp to the rods, using 4 - M5x10mm SHCS, 4 - M5Washers , and 4 - M5 Nuts. The nuts are trapped inside the nutraps in the bottom of the

clamp.

9. Locate the X-Axis Idler End, 1 - Delrin Nut, 2 - M5x10mm SHCS, 2 - M5 Washers, and 4 -8mm Self-Aligning Bronze Bushings. Insert the bushings into the end, and secure the delrin

nut onto the end as well using the screws.

Arrows show where screws go

Bushinglocations,green are

not seen inphoto.


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X-AXIS ASSEMBLY

Page 67

10.Locate the other Delrin Nut and secure it with 2 - M5x10mm SHCS to the X-Axis MotorEnd.


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X-AXIS ASSEMBLY

Page 68

11.Locate the 4 - 10mm Self Aligning Bronze Bushings and press two into the X-Axis MotorEnd and two into the X-Axis Idler End.

12.Set aside and continue with the Z-Axis build up.

1 mm Bushings go here

as well as under theends


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Z-AXIS ASSEMBLY

Whats Needed?

Tools:

2.5mm Hex Key 3mm Hex Key 4mm Hex Key 6mm Hex Key

Hex Key

Spirit/Bubble LevelHardware:

NEMA 17 Stepper Motor x3 M3x10mm x12 M3x16mm x4

M3 Washers x16 M4x18mm SHCS x2 M4 Washers x2 M4 Nuts x2 M5 Nuts x12 M5x10 SHCS x16 M5 Washers x8 M8x30mm SHCS x1 M8 Washers x3 M8 Nuts x1 Leadscrew Couplers x2 10mm Precision Chromed Shaft x2 GT2 Pulley x1 GT2 Belt x1

Plastics:

Z-Axis Rod Clamps x4 Z-Axis Motor Mounts x2 Z- Lower Motor Mount Support (A)

x2 Z- Lower Motor Mount Support (B)

x2 X-Carriage Belt Clip x2

Section

9


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Page 70

Steps:

1. Locate one of the Z-Axis Motor Mounts, a NEMA 17 Stepper Motor, and attach the motormount onto the motor with 4 - M3x10mm, and 4 - M3 Washers. Do not tighten.Also,

insert the 4 - M5 Nuts into the traps in the mounts.

2. Locate 2 - Z-Axis Motor Mount Legs and attach to the motor mount with 2 - M5x10mmSHCS and 2 - M5 Washers.

Arrows show where thenuts go


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Z-AXIS ASSEMBLY

Page 71

3. Attach the motor mount assembly to the right side of the frame with 4 - M5x10mm SHCSand 4 - M5 Washers. Do not tighten.

4. Repeat steps 1-3 with the other mount and attach to the left side of the frame.


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Page 72

5. Locate 1 - Leadscrew Coupler, and attach to the motor using a 3mm hex key as a spacerbetween the coupler and the motor.

6. Repeat for the other motor.7. Locate the X-Axis Assembly, 1 - 10mm Precision Linear Shaft, 4 - M5x10mm SHCS, 2 - Z-

Axis Rod Clamps.


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Page 73

8. Place the X-Axis Assembly on the Y-Axis Table.

9. Position the shaft such that it is fitted into the Z-Axis Top Vertex, securing it with the Z-

Axis Rod Clamp and the SHCS and WASHERS.


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Z-AXIS ASSEMBLY

Page 74

10.Position the bottom of the shaft such that it is in line with the motor mount assembly, andloosely fasten the rod clamp with the screws and washers.

11.Align the shaft such that it is parallel with the frame, if looking from the front: Adjust the Z-Axis Top Vertex in and out of the extrusion to get it even. Tighten the screws when

complete.

Move the top vertex to adjust


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Z-AXIS ASSEMBLY

Page 75

12.If looking from the side: Adjust the Z-Axis Motor Mount Assembly from side to side alongthe extrusion in order to get shaft straight. Tighten down the screws when complete.

13.Repeat for the other side.14.Check the smoothness of travel in the Z direction by lifting the X-Axis Assembly up along

the shaft, taking care not to push through a bind. If this happens, lower the assembly to the

bed, and make an adjustment to the Z-Axis.

Move themotor mount

to adjust


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Z-AXIS ASSEMBLY

Page 76

15.Locate the Precision Leadscrew and start screwing them into the top of the X-Axis MotorEnds Delrin Nut until you reach the Z-Axis Motor Coupling.

16.Adjust the motor back and forth in order to capture the leadscrew end, bottoming it out.


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Z-AXIS ASSEMBLY

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17.Tighten the set screw in the coupling to secure the leadscrew onto the motor. Be careful notto put any undue stress onto the X-Axis.

18.Repeat 16-18 with the other leadscrew.19.Check to see if the leadscrew is parallel with the linear shaft. Adjust it by moving the motor

inside the motor mount back or forth. Tighten the screws once adjusted.

20.Repeat the above step with the other side.

Tighten motormount screwsonce adjustedleadscrew isparallel withthe rod.


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21.Ensure that the X-Axis is parallel with the Y-Axis Table by adjusting one of the leadscrewsup or down.

22.Gather 1 - M8x30mm SHCS, 3 - M8 Washers, and 1 - M8 Nut.23.Arrange the hardware as shown in the photo.

Adjust leadscrews by hand toraise or lower x-axis


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24.Thread the bolt onto the X-End Idler Side, and secure with the washer and nut as shown.

25.Take the last NEMA 17 Stepper Motor and attach the GT2 Pulley to the shaft with the set

screw included with the pulley.


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26.Attach the motor assembly to the X-End - Motor Side with 4 - M3x10mm SHCS and 4 - M3Washers.


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27.Using the X-Axis GT2 Belt, 1 - Belt Clip, 2 - M3x16mm SHCS, 2 - M3 Washers, and 2 - M3Nuts, attach the belt to the X-Carriage on the motor side. Use the nut traps on the underside

of the carriage.

28.Route the belt from the bottom of the motor, around the GT2 Pulley. Continue routingacross to the idler.


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29.Secure to the other side of the X-Carriage with 1 - Belt Clip, 2 - M3x16mm SHCS, 2 - M3Washers, and 2 - M3 Nuts. Remember to tighten the belt so it is taut.


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30.Ensure proper alignment of the pulley and idler by moving the carriage back and forth. Ifthey are misaligned, adjust the position of the belt under the belt clips so that they are closer

or farther from the center of the x-carriage.

31.Place 2 - M4 Nuts into the nut traps on the Extruder flange.

Looking down the belt, makesure that the top run is in line

with the bottom run


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32.Place the hotend on top of the x-carriage.

33.Place the extruder on top of the hotend, note orientation.

34.Using 2 - M4x18mm SHCS, and 2 - M4 Washers, attach the assembly together, but do nottighten it.


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Z-AXIS ASSEMBLY

35.Using a scrap piece of filament that matches the size of the hot end that you are using,thread it through the extruder.

36.The filament will be used to line the hotend with the extruder for a smooth transition. Movethe extruder back and forth while pulling and pushing on the filament. When you feel littleor no resistance, tighten the screws.

A note regarding the method of securing the idler hinge to the main body. Some people use

washers, or springs to provide tension onto the idler. I used a combination of lockwashers,flats and spacers.

PLEASE NOTE: Due to the fact that the community requires this documentation ASAP, I will notbe including the Electronics nor Calibration sections in the initial release. I will follow up with asecond revision that includes these sections.

trinity labs mendelmax 1.5+ build instructions

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