Finished : Mega Prusa i3 Reprap with 400x400x280mm envelope!

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stormychel
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Finished : Mega Prusa i3 Reprap with 400x400x280mm envelope!

Post by stormychel » Thu Jun 11, 2015 3:57 am

I started building this : http://www.instructables.com/id/Mega-Pr ... /?ALLSTEPS a few weeks ago, and it is finished and works :)

Couldn't have done it without my UP! Mini, so I really needed to post this here! The UP!'s accuracy and reliability was a great help in printing the parts for this printer, and making custom parts for it during my build.

Attached are the finished printer minus the extruder, the extruder, and the first successful print (a little too-hot printed PETG, was still playing with variable layer temperatures in Simplify3D. I still need to test and calibrate it thoroughly, but have a severe lack of time these days so it'll have to wait for a while...

For those interested, build cost is in the €550-650's.

Future plans are a custom dual-extruder to be able to use dissolving support and a heated build chamber.
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Last edited by stormychel on Sat Aug 15, 2015 6:54 am, edited 2 times in total.
@stormychel

roller
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by roller » Thu Jun 25, 2015 1:26 am

Can you post some smaller pics please ... when I look at them they chop off most of the right side so I only get a hint of your build. The limitation seems to be due to the forum cropping it.

stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by stormychel » Thu Jun 25, 2015 4:38 am

roller wrote:Can you post some smaller pics please ... when I look at them they chop off most of the right side so I only get a hint of your build. The limitation seems to be due to the forum cropping it.
Yesn the forum is very limiting when it comes to pictures...

Uploaded a few new ones, it's sitting on the bedroom floor because I am expanding my desk to make room for it.

Next up is better cable management (cable chains).

The Raspberry Pi will not be used, the goal was to make it autonomous with Repetier Host, but I bought Simplify3D and like the way it visualizes progress, so I will dedicate an older Mac mini to it.

The machine works very well, had some problems with Y-axis layer shifting but adjusting jerk settings eliminated that. I might decide to swap the belt drive to a lead screw drive later on to fix that without tweaking the firmware too much.

Just got my rafts configured as I want too. I was printing without raft first, but even on kapton tape with no glue stick or hairspray, larger prints stick so hard that they are nearly unremovable, so I deduced to print with a raft. Might play with first-layer temperatures later on to get a little less sticking and print raftless again, as the bed is VERY level and allows it.

Until now, after overcoming some necessary firmware configuration problems, it's been a set-and-forget printer, pretty much like the UP!, and I'm very happy with it :)
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stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by stormychel » Thu Jul 02, 2015 4:45 pm

Just managed to mimic the raft quality of the UP! on my Reprap. Nice :D
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LonV
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by LonV » Fri Jul 03, 2015 6:57 am

How did you do that? I've never gotten good rafts or support remove from my RepRap. :D

stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by stormychel » Fri Jul 03, 2015 7:12 pm

:)

Simplify3D, but stock settings didn't work for me. This worked :

- 3-layer raft with base layers
- 85% infill
- raft printed at normal temperature
- skip one layer
- print first layer of part 10 degrees colder
- print second layer of part 5 degrees hotter
- let cool completely, then take off the raft with the same ease as the PP3DP ones :)
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LonV
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by LonV » Fri Jul 03, 2015 8:36 pm

Wow, nice! Thanks for sharing.

-Lon

stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by stormychel » Fri Jul 03, 2015 9:25 pm

You're welcome :)
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roller
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by roller » Sat Jul 25, 2015 4:09 pm

Fantastic. Very nice work. How's your print quality going?

I think my next build is going to be a very larger (800mm+) CoreXY design but I my wallet hurts every time I budget out the design.

stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by stormychel » Sat Jul 25, 2015 4:14 pm

roller wrote:Fantastic. Very nice work. How's your print quality going?

I think my next build is going to be a very larger (800mm+) CoreXY design but I my wallet hurts every time I budget out the design.
Thanks :)

Print quality is great, had some Y-layer shifting issues in the beginning because of the large / heavy bed, but those are gone now. The only remaining challenge is getting those large prints to stick, and still get them removed from the print bed...

Josef Prusa is working on a CoreXY printer, wonder what he's going to come up with...
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roller
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by roller » Sun Jul 26, 2015 11:35 am

The problem I have with Josef Prusa and his designs is that he is a bit of an evangelist and tends to compromise printer design for the sake of meeting the tenants of the reprap community. I'd rather have a printer that put print quality first and less emphasis on it being built from printed parts and basic vitamins.

stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by stormychel » Sun Jul 26, 2015 11:52 am

roller wrote:The problem I have with Josef Prusa and his designs is that he is a bit of an evangelist and tends to compromise printer design for the sake of meeting the tenants of the reprap community. I'd rather have a printer that put print quality first and less emphasis on it being built from printed parts and basic vitamins.
True... but he hated my idea of a printed frame so there is still hope ;)
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roller
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by roller » Mon Aug 03, 2015 6:50 am

I don't know him well enough to really comment but from previous discussions with him a long time ago he seemed to stubbornly push his own ideas and took a long time to come to the merits of the ideas of others.

stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by stormychel » Mon Aug 03, 2015 6:54 am

roller wrote:I don't know him well enough to really comment but from previous discussions with him a long time ago he seemed to stubbornly push his own ideas and took a long time to come to the merits of the ideas of others.
Maybe that's why he still hasn't come up with a CoreXY design, while there are already a few very nice versions. RepRap version : https://github.com/jand1122/RepRap-XY

I discuss with him regularly, and wanted to buy my filament and parts from his store to support development, but the filament range is very narrow, shipping costs are high and he only supplies 3mm hotends while 1.75 is just fine for me.
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roller
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by roller » Mon Aug 03, 2015 7:00 am

Ah yes, another point of stubbornness ... the 3mm hotends/filament :)

stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by stormychel » Mon Aug 03, 2015 7:06 am

roller wrote:Ah yes, another point of stubbornness ... the 3mm hotends/filament :)
;)
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stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x400mm envel

Post by stormychel » Sat Aug 15, 2015 6:52 am

Printed this 160mm long, 3mm thick, 100% infill ABS wrench in 8 minutes. No lifting, no delamination... so happy with this build :)
The surface quality is a little raw because I did not print the last layer slower, I needed this thing quickly!
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stormychel
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Re: Finished : Mega Prusa i3 Reprap with 400x400x280mm envel

Post by stormychel » Sat Aug 15, 2015 6:58 am

Another example, a mudguard for my girlfriend's wheelchair, printed in black PLA, with the last 20 layers in pink PLA (no dual extruder yet, just pause, swap, continue.

This part is about 350x300x60mm and took 6 hours to print on 0.30 layer height.
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