Build Manual v1.

1
WWW.GADGETS3D.COM WWW.GADGETS3D.EU
INTRODUCTION

AIM: This manual is designed to provide all the information needed to the build G3D
RepRap 3D printer (based on the Prusa i3 - with its further modifications). Description
created with the aim to describe step by step how to build a 3D printer RepRap G3D.

AUTHOR: Rafal Tomasiak (rt@gadgets3d.com)

PUBLISHER: GADGETS3D (www.gadgets3d.com/www.gadgets3d.eu)

LICENSE: GPL (http://reprap.org/wiki/GPL)

DOCUMENT: If you have any questions, suggestions, etc. about this document, please
contact me (rt@gadgets3d.com)

Introduction 3
TABLE OF CONTENT

1 Bill Of Materials 5

2 Mounting The Z Axis Motor To The Frame 11

3 Frame Assembly 18

4 Y Axis Frame Assembly 21

5 Y Axis Frame Calibration 32

6 Platform Assembly 34

7 Z Axis Endstop Assembly 39

8 Mounting X Axis/Y Axis 42

9 X Carriage Mount 46

10 Mounting X Axis/Y Axis Part II 48

11 Frame Up + LCD (optional) 50

12 Hot End Mount 61

13 Extruder 64

14 X Axis Belt Assembly 77

15 Z Axis Drive Assembly 81

16 Printing Platform Assembly 84

17 X Axis/Y Axis Endstop Installation 88

18 Electronics Assembly 92

19 Electronics Calibration 113

20 Importing Slic3r Profiles

14.01.2014 Table Of Content 4

 1
BILL OF MATERIALS

1.1 Acrylic Parts

1x Frame A 1x Frame B

1 2

1x Frame C 1x Frame Up

3 4

2x Y Idler (Part P2) 1x Y Belt Tensioner (Part P3)

5 6

1x Motor Mount (Part P4) 1x Y Endstop Mount (Part P5)

7 8

1x X Endstop Mount (Part P6) 2x Frame Up Bracket (Part P7)

9 10

2x Z Endstop Mount (Part P8) 2x Z Rods Mount ( Part P8-1)

11 12

1x Spool Holder (Part P9) 1x Spool Holder (Part P10)

13 14

Bill Of Materials 5
 1

1x Spool Holder (Part P11)

15

1x Spool Holder (Part P12)

16

2x Spool Holder (Part P13)

17

2x Z Motor Mount (Part P14)

18

4x Z Motor Mount (Part P15)

19

1x Platform A

20

1x Platform B

21

Bill Of Materials 6
 1

1.2 Printed Parts

1x Extruder Small Gear 1x Extruder Big Gear

1 2

1x Extruder Motor Mount 1x Hot End Mount

3 4

1x Additional Fan Mount 1x Extruder Idler

5 6

1x X Carriage Mount 1x X End Motor Mount

7 8

1x X End Idler Mount Right 4x Corner

9 10

1x Y Belt Clamp 1x LCD Kill Button

11 12

Bill Of Materials 7
 1

1.3 Screws, Nuts, Washers

SCREWS: BAG:
M3x10 A1
M3x12 A2
M3x16 A3
M3x16 A4
M3x16 A5
M3x20 A6
M3x25 A7
M3x30 A8
M3x40 A9
M3 FOR PLATFORM A10
SMALL SCREWS FOR FASTENING EXTRUDER SMALL GEAR A11
M5x20 A12
M5x30 A13
M5x16 A14
NUTS: BAG:
M3 B1
M3 NYLOCK B2
M5 B3
M8 B4
WASHERS: BAG:
M3 C1
M8 C2

1.4 Smoothed and Threaded Rods

NAME: QTY: BAG:

M8 SMOOTHED RODS FOR X AXIS 2x E6
M8 SMOOTHED RODS FOR Y AXIS 2x E5
M8 SMOOTHED RODS FOR Z AXIS 2x E4
M8 THREADED RODS Y AXIS (SHORT) 3x E1
M8 THREADED RODS Y AXIS (MEDIUM) 1x E2
M8 THREADED RODS Y AXIS (LONG) 2x E3
M5 THREADED RODS Z AXIS 2x E7

Bill Of Materials 8
 1

1.5 Motors, Electronics, Cables, Endstops, Hotend

NAME: QTY:
RAMPS 1.4 PCB 1x
G3D STEPPER DRIVERS FOR X MOTOR 1x
G3D STEPPER DRIVERS FOR Y MOTOR 1x
G3D STEPPER DRIVERS FOR Z MOTOR 1x
G3D STEPPER DRIVERS FOR EXTRUDER 1x
MEGA 2560 rev3 1x
SD RAMPS 1x
POWER SUPPLY 1x
2PIN CABLE FOR THERMISTOR 2x
3PIN CABLE FOR X ENDSTOP 1x
3PIN CABLE FOR Y ENDSTOP 1x
3PIN CABLE FOR Z ENDSTOP 2x
5PIN CABLES FOR X MOTOR 1x
5PIN CABLE FOR Y MOTOR 1x
5PIN CABLE FOR Z MOTOR 2x
5PIN MOTOR FOR EXTRUDER MOTOR 1x
NEMA17 STEPPER MOTOR FOR X AXIS 1x
NEMA17 STEPPER MOTOR FOR Y AXIS 1x
NEMA17 STEPPER MOTOR FOR Z AXIS 2x
NEMA17 STEPPER MOTOR FOR EXTRUDER 1x
G3D FAN SPLITTER 1x
G3D COOLING PLATE 1x
FAN COOLER 3x
CERAMIC SCREWDRIVER 1x
G3D HOTEND (PRE-ASSEMBLED) 1x
NOZZLE 0.4mm 1x
NOZZLE 0.5mm 1x

Bill Of Materials 9
 1

1.6 Bearings, Pulleys, Belts

NAME: QTY: BAG:

BEARING FOR Y AXIS 1x F1
BEARING FOR X AXIS 2x F1
LINEAR BEARINGS FOR PLATFORM 3x F2
LINEAR BEARINGS FOR X END MOTOR 2x F3
LINEAR BEARINGS FOR X END IDLER 2x F3
LINEAR BEARINGS FOR X CARRIAGE 3x F3
BEARINGS FOR Z THREADED RODS 2x F4
BEARING FOR EXTRUDER IDLER 1x F5
BEARING FOR HOBBED BOLT 1x F5
GT2 PULLEY FOR Y AXIS 1x G1
GT2 PULLEY FOR Y AXIS 1x G1
GT2 BELT FOR X AXIS 1x H1
GT2 BELT FOR Y AXIS 1x H1

1.7 Addons

PLA FILAMENT 1kg 1x

PAPER TAPE 1x
OTHER UNALLOCATED PARTS 1x
CONFIGURED MARLIN FIRMWARE (SOON) 1x
CONFIGURED SLIC3R PROFILE (SOON) 1x
DOCUMENTATION (IN PREPARATION) 1x

1.8 Tools required

- HEX KEY SET (M3, M4, M5, M6, M8)

- SCREWDRIVERS
- KEY TO THE NUTS M8 2x
- SOLDERING IRON + TIN
- CALIPER OR RULER
- PLIERS
- INSULATING TAPE

Bill Of Materials 10
 2
MOUNTING THE Z AXIS MOTOR
TO THE FRAME

2.1 Prepare:

• acrylic part P14 x 2

• acrylic part P15 x 4
• screw A1 x 10
• screw A5 x 4
• nut B1 x 4
• washer C1 x 14
• motor D1 x 2
• screwdriver

Mounting The Z Axis Motor To The Frame 11

 2

2.2 Apply part P14 on motor in a such way

2 that a hole is outside.

2.3 Assembly element with screws, washers

3 and nuts.

4 2.4 Similarly repeat steps for the other side.

Mounting The Z Axis Motor To The Frame 12

 2

2.5 Take part P15 and assembly it to P14

using A5 screw,C1 washer and nut B1.
7 Similarly repeat steps for the other side.

Mounting The Z Axis Motor To The Frame 13

 2

2.6 Proper assembly is shown above.

* In order to improve the visual of our printer, we can use masking for the wires.

Mounting The Z Axis Motor To The Frame 14

 2

2.7 Prepare:

• acrylic part Frame A

• screw A5 x 6
• nut B1 x 6
• washer C1 x 6
• pre-assembled parts
• screwdriver

Mounting The Z Axis Motor To The Frame 15

 2

2.8 Place the pre-assembled parts into the

10 frame, insert cables into the holes.

2.9 Take the screw A5 with a washer C1

and nut B1 then tighten pre-assembled part
11 to the frame.

2.10 Similarly repeat the process for the

12 other side.

Mounting The Z Axis Motor To The Frame 16

 2

13

2.11 Proper assembly is shown above.

Mounting The Z Axis Motor To The Frame 17

 3
FRAME ASSEMBLY

14

3.1 Prepare:

• acrylic part Frame A with pre-assembled Z-axis motors

• acrylic part Frame B
• acrylic part Frame C
• screw A5 x 6
• nut B1 x 6
• washer C1 x 6

Frame Assembly 18
 3

15 16

3.2 Place part Frame B and Frame C into Frame A holes (Part B should be on the left side
from front view).

17

3.3 Assembly parts using screws A5 with washers C1 and nuts B1.

Frame Assembly 19
 3

18

3.4 Proper assembly is shown above.

Frame Assembly 20
 4
Y AXIS FRAME ASSEMBLY

19

4.1 Prepare:

• nut B4 x 12
• washer C2 x 12
• rod E3 x 2
• rod E5 x 2
• printed part Corner x 4

Y Axis Frame Assembly 21

 4

20 21

4.2 Thread the nut B4 onto rod E3, slip two washers C2 and thread another nut B4 to its
half. Similarly repeat process for other rod. Then thread another nut B4 onto rod E3 and slip
washer C2. Similarly repeat step for the other rod E3.

22 23

4.3 Insert printed part Corner into rods then slip washer C2 and thread nut B4
(do not tighten). Similarly repeat process for the other rod E3.

Y Axis frame Assembly 22

 4

24

4.4 Place rod E5 onto printed parts Corner. Similarly repeat for other
pre-assembled part.

Y Axis Frame Assembly 23

 4

25

4.5 Prepare:

• rod E1 x 2
• nut B4 x 14
• washer C2 x 14
• acrylic part P2 x 2
• bearing F1
• screw A13
• nut B3 x 2
• pre-assembled parts

Y Axis frame Assembly 24

 4

26 27

4.6 Slip washer C2 onto rod E1 and thread two nuts B4 then slip another washer C2. Then
insert into rods acrylic part P2, slip washer C2 and thread the nut B4. Repeat process for
the other rod.

28 29

4.7 Insert another acrylic part P2, thread two nuts B4 and slip washer C2.

Y Axis Frame Assembly 25

 4

30

4.8 Prepare pre-assembled parts.

31 32

4.9 Insert Y axis front part into printed parts Corner. Slip washer C2 and thread the nut B4
into rods.

Y Axis frame Assembly 26

 4

33

34

4.10 Insert screw A13 with bearing F1

into acrylic part P2 then thread two nuts B3.
Be careful while tightening part P2, leave
some space otherwise bearing will not work
35 properly.

Y Axis Frame Assembly 27

 4

36

4.11 Prepare:

• rod E1
• rod E2
• nut B4 x 24
• washer C2 x 12
• acrylic part P3
• screw A8
• plastic spacer I1 x 2
• nut B2
• acrylic part P4
• motor D1
• gear G1
• screw A1 x 2
• washer B1 x 2
• acrylic part P5

Y Axis frame Assembly 28

 4

4.12 Place gear G1 onto motor shaft, tighten

37 it using screws inside gear.

4.13 Assembly motor to acrylic part P4 us-

38 ing screws A1 and washers B1.

4.14 Insert pre-assembled motor onto rods

E1 and E2, tighten it with nuts B4 from both
sides. Rod E1 should be inserted into bottom
39 hole of acrylic part P4.

4.15 Insert a screw A8 with two plastic

40 spacers I1 and nut B2 into acrylic part P3.

Y Axis Frame Assembly 29

 4

4.16 Thread the nut B4 onto rod E1 and E2

then slip acrylic part P3 and thread two nuts
41 B4.

4.17 Slip acrylic part P5 onto rod E1 and E2,

42 thread two nuts B4 and washers C2.

4.18 On the other end of rods thread the nut

43 B4 and washer C2.

4.19 Insert pre-assembled part into printed

parts Corner, then slip washer C2 and nut B4
44 to lock element. Do not tight nuts yet.

Y Axis frame Assembly 30

 4

45

4.20 Thread the nut B4 then slip washer C2 onto rod E2. Repeat this
step for the other side.

46 47

4.21 Now we can insert our pre-assembled part into Frame A. Slip washers C2 and thread
nut B4 to assembly element to Frame B and Frame C.

Y Axis Frame Assembly 31

 5
Y AXIS FRAME CALIBRATION

48

5.1 Distance between printed parts Corner should be 150mm use

ruler or caliper, then tighten the nuts to lock this distance.

49

5.2 Repeat last step for the other side.

Y Axis Frame Calibration 32

 5

5.3 Now set up motor gear, Frame A hole

50 and bearing in a straight line.

5.4 Part P3 (belt tensioner) should be set like

51 on picture.

5.5 If everything is adjusted, we can tighten

52 all nuts B4. Skip tightening parts P5 and P3.

Y Axis Frame Calibration 33

 6
PLATFORM ASSEMBLY

53

6.1 Prepare:

• acrylic part Platform A

• bearing F2 x 3
• rod E5 x 2
• timing belt H1
• screw A14 x 12
• screw A1 x 2
• screw A8
• nut B2
• printed part Y Belt Clamp
• plastic spacer I1 x 2

Platform Assembly 34
 6

54 55

6.2 Place bearings onto Platform A and screw them using screws A14.

56

6.3 Use screws A1 to assembly printed part Y Belt Clamp to

Platform A.

Platform Assembly 35
 6

6.4 Insert one end of timing belt into Y Belt

57 Clamp.

6.5 Insert smooth rods from already at-

tached frame into bearings. Be careful while
inserting rods, do it in a straight line or you
58 will damage bearings.

6.6 Now insert pre-assembled platform with

59 rods onto printed parts Corner.

6.7 Now use zip-ties to lock rods with printed

part Corner for each side. Tighten the zip-ties
60 so rodcs can not move.

Platform Assembly 36
 6

61

62

63

6.8 Now make a loop with timing belt around

motor gear then again make a loop around
bearing in front of the printer. Now insert the
end of timing belt to the printed part Y Belt
64 Clamp.

Platform Assembly 37
 6

65

6.9 Now we can set up belt tensioner part P3 and tighten the screws
to lock it.

Platform Assembly 38
 7
Z AXIS ENDSTOP ASSEMBLY

66

7.1 Prepare:

• endstop J1 x 2
• acrylic part P8-1 x 2
• screw A5 x 4
• screw A1 x 4
• nut B1 x 4

Z Axis Endstop Assembly 39

 7

67

7.2 Assembly endstop J1 using screw A1 to acrylic part P8.

68

7.3 Repeat last step for the other endstop.

Z Axis Endstop Assembly 40

 7

69

70

7.4 Now attach acrylic part P8-1 with end-

stop to Frame A using screws A5 and nuts
71 B1. Slip the wires trough holes.

Z Axis Endstop Assembly 41

 8
MOUNTING X AXIS/Y AXIS

72

8.1 Prepare for the right side on the X axis/Y axis:

• printed part X End Idler Mount Right

• bearing F3 x 2
• bearing F1 x 2
• screw A14
• nut B3 x 2

Mounting X Axis/Y Axis 42

 8

8.2 Insert two bearings F3 into printed part

73 X End Idler Mount Right.

8.3 Insert two bearings F1 into X End Idler

Mount Right and insert screw A14 trough
74 them then thread nut B4.

8.4 Now put nut B3 into printed part, if the

connection is loose use glue to lock the nut
75 into printed part.

Mounting X Axis/Y Axis 43

 8

76

8.5 Prepare for the left side on the X axis/Y axis:

• printed part X End Motor Mount

• motor D1
• bearing F3 x 2
• screw A5 x 3
• washer C1 x 3
• gear G1
• nut B3

Mounting X Axis/Y Axis 44

 8

8.6 Insert two bearings F3 into printed part

77 X End Motor Mount.

8.7 Assembly motor for x-axis using screws

78 A5 with washers C1.

8.8 Insert gear onto motor shaft to its end

79 and tighten the screws inside it.

8.9 Now put nut B3 into printed part, if the

connection is loose use glue to lock the nut
80 into printed part.

Mounting X Axis/Y Axis 45

 9
X CARRIAGE MOUNT

81

9.1 Prepare:

• printed part X Carriage Mount

• rod E6 x 2
• bearing F3 x 3
• zip-tie x 6

X Carriage Mount 46
 9

82 83

9.2 Insert bearings F3 into X Carriage Mount.

84 85

9.3 Slip zip-ties trough the holes and tighten the bearing to printed part.

X Carriage Mount 47
 10
MOUNTING X AXIS/Y AXIS PART II

86 10.1 Insert rods E6 into printed part.

10.2 Insert pre-assembled X Carriage Mount

87 into rods.

10.3 Now insert printed part to the end of

88 the rods E6.

Mounting X Axis/Y Axis Part II 48

 10

10.4 Now attach X Endstop Mount to printed

89 part X End Motor Mount using screws A1.

10.5 Carefully insert rods E4 into bearings

90 placed in printed parts.

10.6 Now attach pre-assembled part to

the printer, E4 rods should fit the holes in
pre-assembled Z axis motors on the bottom
91 of the printer.

Mounting X Axis/Y Axis Part II 49

 11
FRAME UP + LCD (OPTIONAL)

92

11.1 Prepare:

• acrylic part Frame Up

• LCD panel (optional)
• LCD knob
• printed part LCD Kill Button
• plastic spacer I1 x 4
• screw A7 x 4
• nut B2 x 4
• washer C1 x 4

Frame Up + LCD (optional) 50

 11

93

94

95

11.2 Assembly acrylic part Frame Up, take

screws A7 and plastic spacers, insert LCD
Kill Button printed part, then fit LCD panel
and use nuts B2 to tighten panel to spacers.
96 Then apply LCD knob from front.

Frame Up + LCD (optional) 51

 11

97

11.3 Proper assembly is shown above.

Frame Up + LCD (optional) 52

 11

98

11.4 Prepare:

• pre-assembled Frame Up part

• acrylic part P7 x 2
• screw A5 x 4
• washer C1 x 4
• nut B1 x 4

Frame Up + LCD (optional) 53

 11

99

100

11.5 Insert nut into hole in part P7 and then

use screws A5 to assembly part to Frame A.
Part P7 is not symmetric, attach it so noth-
101 ing will stick out.

Frame Up + LCD (optional) 54

 11

102

11.6 Proper assembly is shown above.

Frame Up + LCD (optional) 55

 11

103

11.7 Prepare:

• screw A5 x 4
• washer C1 x 4
• nut B1 x 4
• pre-assembled Frame Up part

Frame Up + LCD (optional) 56

 11

104

11.8 Now assembly acrylic part Frame Up to your pinter, do not force
parts to fit, you can damage acrylic parts by doing this.

105 106

11.9 If everything fits, use screws A5 with washers and nuts B1 to lock parts.

Frame Up + LCD (optional) 57

 11

107

11.10 Prepare:

• acrylic part P8 x 2
• bearing F4 x2
• screw A5 x 6
• washer C1 x 6
• nut B2 x 6

Frame Up + LCD (optional) 58

 11

108 11.11 Put bearing into holes.

11.12 Insert screws A5 with washers C1

109 into acrylic part P8.

11.13 Now assembly acrylic part P8

110 to acrylic part Frame Up.

Frame Up + LCD (optional) 59

 11

111

11.14 Similarly repeat last step for the other side. Proper assembly is
shown above.

112

11.15 Now use nuts B2 and tighten part P8 to Frame Up. Be careful
and while tightening screws remember to leave some space between
acrylic parts otherwise you will damage them.

Frame Up + LCD (optional) 60

 12
HOT END MOUNT

113

12.1 Prepare:

• printed part Hot End Mount

• screw A8 x 2
• nut B1 x 2
• washer C1 x 2

Hot End Mount 61

 12

114

12.2 Insert screws trough the holes in printed part X Carriage Mount.

115

12.3 Insert nuts into holes in printed part Hot End Mount.

Hot End Mount 62

 12

116 117

12.4 Now assembly parts using screwdriver.

118

12.5 Proper assembly is shown above.

Hot End Mount 63

 13
EXTRUDER

119

13.1 Prepare:

• Hot End set

• printed part Additional Fan Mount
• 40mm fan
• nut B2 x 4
• screw A5 x 2
• screw A6 x 4
• washer C1 x 4
• fan overlay

Extruder 64
 13

120 121

13.2 Remove two screws from Hot End part.

122 123

13.3 Install printed part Additional Fan Mount using longer screws A5 with washers C1.

Extruder 65
 13

124 125

13.4 Put two screws A6 trough the holes in printed part and fit the fan with overlay, than use
nuts B2 to lock it.

126 127

13.5 Similarly repeat this step with shorter screws for the other side. Then bend fan overlay
so the air stream from fan will point at nozzle’s end.

Extruder 66
 13

128

129

130

13.6 Bend fan overlay, first make two side

walls then bend the biggest one, lock this
position using latches. Proper assembly is
shown in the picture 131.

131

Extruder 67
 13

132

13.7 Prepare:

• printed part Extruder Motor Mount

• printed part Extruder Idler
• printed part Extruder Small Gear
• printed part Extruder Big Gear
• Hobbed Bolt (of Hot End set)
• screw A9 x 2
• screw A7x 1
• screw A6x 2
• screw A1x 4
• screw A11 x 1
• washer C1 x 9
• washer C2 x 2
• nut B1 x 6
• nut B4 x 2
• bearings F5 x 3
• motor D1 x 1

Extruder 68
 13

133

134

13.8 Insert nut B1 into printed part Extruder

Idler hole, than attach it to printed part
Extruder Motor Mount and tighten using
135 screw A7.

Extruder 69
 13

136

137

13.9 Put bearing into printed part Extruder

Motor Mount from both sides, then put bear-
ing into Extruder Idler, interior ring should lock
in printed part so the exterior ring will rotate
138 without friction.

Extruder 70
 13

139 13.10 Insert Hobbed bolt trough bearings.

13.11 Then slip two washers and nut on

hobbed bolt. Do not overtighten the nut,
hobbed bolt should rotate without friction
140 caused by tightening.

13.12 Now slip Extruder Big Gear onto

Hobbed bolt and use nut to lock it. Counter
nuts so hobbed bolt can rotate without
141 friction caused by tightening.

13.13 Proper assembly is shown on the

142 picture.

Extruder 71
 13

143 13.14 Put nuts into holes.

13.15 Insert two long screws into printed

part Extruder Idler (use spring between parts
144 - optional).

145 13.16 Assembly parts by tightening screws.

Extruder 72
 13

146 147

13.17 Insert nut into printed part hole then use screw A11, you can also use replacement
screw like on picture above but we recommend using A11. Then put printed part onto motor
shaft and tighten the screw.

148

13.18 Proper assembly is shown above.

Extruder 73
 13

149

150

13.19 Assembly motor to printed part Ex-

truder Motor Mount using screws A1 with
151 washers.

Extruder 74
 13

13.20 Tighten two gears, connection can

be loose but also can not be overtightened.
Gears should rotate without friction caused
152 by over tightening.

13.21 Prepare bottom part of extruder and

153 already assembled top part of extruder.

154 155

13.22 Insert screws into printed part, then put Hot End part.

Extruder 75
 13

156 157

13.23 Now put top part of extruder with motor and use nuts to lock parts.

Extruder 76
 14
Z AXIS BELT ASSEMBLY

158

14.1 Prepare:

• timing belt GT2 H1

Z Axis Belt Assembly 77

 14

159 160

14.2 Make a loop around the gear using timing belt GT2.

161

14.3 Top end part of timing belt insert into X Carriage Mount.

Z Axis Belt Assembly 78

 14

162 163

14.4 Bottom end part of timing belt drag trough printed part X End Idler Mount Right.

164 165

14.5 Similarly make another loop around the bearing and drag belt to X Carriage Mount
printed part.

Z Axis Belt Assembly 79

 14

166 167

14.6 Stretch the timing belt GT2 and put its end into X Carriage Mount to lock it.

Z Axis Belt Assembly 80

 15
Z AXIS DRIVE ASSEMBLY

168

15.1 Prepare:

• rod E7
• coupler - PTFE tube
• zip-tie x 4 (optional)

Z Axis Drive Assembly 81

 15

169

15.2 Slip PTFE tube onto Z-axis motor shaft. Remember to split it to
the end of the shaft.

170 171

15.3 Then insert threaded rod E7 starting from top, it should go trough bearing placed in
Frame Up acrylic part then trough nut B3 placed in printed parts and finally goes into PTFE
tube. Remember to thread the threaded rod to the end of PTFE coupler.

Z Axis Drive Assembly 82

 15

172

15.4 Proper assembly is shown above.

173

15.5 Optional you can use zip-ties to tighten PTFE tube to shaft and
threaded rod.

Z Axis Drive Assembly 83

 16
PRINTING PLATFORM ASSEMBLY

174

16.1 Prepare:

• acrylic part Platform B

• screw A8 x 4
• nut A10 x 4
• washer C1 x 4
• spring x 4

Printing Platform Assembly 84

 16

175 176

16.2 Put a washer and spring onto screw A8 then such assembled screw insert into already
assembled Platform A.

177 178

16.3 Now put Platform B on the screws on Platform A.

Printing Platform Assembly 85

 16

179 180

16.4 Push the Platform B so screw pop up on the top of platform B.

181

16.5 Now push the table to lock the screws.

Printing Platform Assembly 86

 16

182 183

16.6 Now squeeze gently platform B with platform A and thread nuts A10 on the screws.
Remember to keep the same distance between platforms, especially when you tighten the
screws. Check the distance using ruler or caliper.

* Before printning you should remember to secure Platform B by tape or other material,
* never print on acrylic parts or you damage them.
Printing Platform Assembly 87
 17
X AXIS/Y AXIS ENDSTOP INSTALLATION

184

17.1 Prepare for X axis Endstop:

• endstop
• screw A1 x 2

X Axis/Y Axis Endstop Installation 88

 17

185 186

17.2 Insert two screws into X Endstop Mount P6 and screw the endstop.

187 188

17.3 Then check if your endstop works by moving X Carriage printed part, if it hits endstop
it’s good.

X Axis/Y Axis Endstop Installation 89

 17

189

17.4 Prepare for Y axis Endstop:

• endstop
• śruba A1 x 2

X Axis/Y Axis Endstop Installation 90

 17

190 191

17.5 Fit endstop to acrylic part Y Endstop Mount P5 then screw endstop into it. Now move
platform and adjust endstop. Platform should hit endstop.

X Axis/Y Axis Endstop Installation 91

 18
ELECTRONICS ASSEMBLY

192

18.1 Prepare:

• COOLING FAN (plastic spacer, nuts, bolts)

• FAN SPLITTER
• LCD G3D SHIELD
• CS RAMPS 1.4 (RAMPS, Arduino Mega 2560)
• screw A3 x 8
• nut B1 x 8
• power supply DC 12-14V 5A
• voltmeter or multimeter
• ceramic flat screwdriver
• USB cable

Electronics Assembly 92
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193 194

18.2 Carefully separate RAMPS board and Arduino Mega 2560.

195 196

18.3 Prepare FAN SPLITTER plate and Arduino Mega 2560 with screws A3 x 8 and
nuts B1 x 8.

Electronics Assembly 93
 18

197 198

18.4 Fasten both boards to side part Frame B using screws and nuts.

199 200

18.5 Install two long plastic spacers onto RAMPS board using two plastic nuts.

Electronics Assembly 94
 18

201 202

18.6 Proper assembly is shown above.

203

18.7 Then carefully join RAMPS plate with Arduino plate attached to
the side of the printer Frame B. Now connect wires according to the
wiring diagram.

Electronics Assembly 95
 18

204 205

18.8 To connect step motor. First cut off some heat shrink tube (one piece for one connec-
tion) it means we need at least four pieces for one motor. Then slip each piece on each color
of the wire.

206 207

18.9 Now twist wires together from motor and wire connector (twist the same color of the
wire together).

Electronics Assembly 96
 18

208 209

18.10 Now slip heat shrink tube on this twisted connection.

210 211

18.11 Use heat stream to shrink the tube (you can use lighter or heat gun).

Electronics Assembly 97
 18

212

18.12 Stepper motor circuit diagram.

Electronics Assembly 98
 18

213

214

215

18.13 Connect motor wires in order:

216 extruder, X axis, Y axis, Z axis.

Electronics Assembly 99
 18

217

18.14 Then connect thermistor.

218

18.15 Thermistor circuit diagram.

Electronics Assembly 100

 18

219 220

18.16 Cut off two pieces of heat shrink tube.

221 222

18.17 Slip heat shrink tube onto wires, then twist wires from endstop connector to endstop
output (endstop circuit diagram is shown on the picture 227).

Electronics Assembly 101

 18

223 224

18.18 Then slip heat shrink tube on this connection and use heat gun or lighter to shrink the
tube.

225 226

18.19 Then connect endstop wires in order: X axis, Y axis, Z axis according to circuit
diagram to axis-min pins.

Electronics Assembly 102

 18

227

18.20 Endstop circuit diagram.

Electronics Assembly 103

 18

228

18.21 Next connect ceramic heater wires to output D10, use screw-
driver to lock it.

229

18.22 Hot End circuit diagram.

Electronics Assembly 104

 18

230 231

18.23 Connect the power supply for FAN SPLITTER board (you can use one of the thermistor
wires from RAMPS 1.4 CS set).

232

18.24 FAN SPLITTER circuit diagram.

Electronics Assembly 105

 18

233 234

18.25 Attach short plastic spacer to G3D LCD SHIELD using plastic nut.

235 236

18.26 Then carefully install LCD SHIELD G3D and connect wires to the display: EXP1 to
EXP1 and EXP2 to EXP2.

Electronics Assembly 106

 18

237

18.27 Next remove two big screws from COOLING FAN to separate
two plates.

238 239

18.28 Using the hex key and three screws from set and attach bottom plate of COOLING
FAN to spacers.

Electronics Assembly 107

 18

240

18.29 Then put top plate of COOLING PLATE with fans and screw it
using big screws.

241

18.30 Last step is to connect fans from COOLING PLATE and extruder
fan to the FAN SPLITTER board. Remember about polarity otherwise
fans will not work.

Electronics Assembly 108

 18

242

243

18.31 Cut off two pieces of heat shrink

tube, slip these pieces onto wires (thermistor
wire with two-pin connector from RAMPS 1.4
CS set). Then twist wires together and use
stream of heat to shrink tube over the
244 connection.

Electronics Assembly 109

 18

245

18.32 FAN SPLITTER fans circuit diagram.

Electronics Assembly 110

 18

246

18.33 Proper electronics assembly is shown above.

247

18.34 After installing filament spool your printer is ready to print.

Electronics Assembly 111

 18

248

18.35 RepRap G3D circuit diagram.

Electronics Assembly 112

 19
ELECTRONICS CALIBRATION

249 250

19.1 Arduino Mega 2560 system does not have a preloaded firmware. Go to the page:

http://arduino.cc/en/Main/Software

Download software called Arduino 1.0.5 then connect via USB RAMPS electronics.
To install needed drivers we need to proceed with the following steps:

1. Plug in your board and wait for Windows to begin it’s driver installation process. After
a few moments, the process will fail, despite its best efforts.

2. Click on the Start Menu, and open up the Control Panel.

3. While in the Control Panel, navigate to System and Security. Next, click on System.
Once the System window is up, open the Device Manager.

4. Look under Ports (COM & LPT). You should see an open port named „Arduino UNO
(COMxx)”.

5. Right click on the „Arduino UNO (COmxx)” port and choose the „Update Driver Software”
option.

6. Next, choose the „Browse my computer for Driver software” option.

7. Finally, navigate to and select the driver file named „arduino.inf”, located in the „Drivers”
folder of the Arduino Software download (not the „FTDI USB Drivers” sub-directory). If you
are using an old version of the IDE (1.0.3 or older), choose the Uno’s driver file named
„Arduino UNO.inf”.

8. Windows will finish up the driver installation from there.

Electronics Calibration 113

 19

251

19.2 After successful installation, open the software Arduino,

by default it will open blank sketch. Now we need to download
pre-configured firmware from this site:

http://gadgets3d.com/firmware/RRG3D.zip

RAMPS 1.4 CS electronics also works with other

firmware variations, such as: Sprinter, Teacup, sjfw, Sailfish.
Preferred firmware: Marlin.

Electronics Calibration 114

 19

252

19.3 From the menu, choose File> Open, and then look forfirmware
in downloads folder. Browse to the folder and look for file Marlin for
Prusa i3 with extensions .ino.

Electronics Calibration 115

 19

253 254
19.4 Now select the menu Tools> Board - Arduino Mega 2560 or Mega ADK and then
Tools> Serial port - COM7 (number can bediffer).

Electronics Calibration 116

 19

255

19.5 Next step is to upload the firmware to electronics by clicking

button with arrow signed „Load”.

Electronics Calibration 117

 19

256 257

19.6 Sketch will be compiled and loaded into the Arduino, during this operation, the LED
should blink. The program displays information about the correct code is loaded. After
uploading the firmware we are almost ready to go. Now you need to calibrate the stepper
motor drivers.

Caution! Potentiometer VREF for stepper motor drivers should be turned maximum
anti-clockwise before connecting power.

Electronics Calibration 118

 19

258 259

19.7 Connect the power supply to the board like shown on circuit diagram (picture 248).
For this task you need a multimeter or a voltmeter and ceramic flat screwdriver.

260 261

19.8 Now applying the measuring tip to the VREF (plus) and GND (ground) check voltage
difference. Calibrate drivers by increasing the voltage on the potentiometer VREF, to do this
you need ceramic screwdriver.

Electronics Calibration 119

 19

262

19.9 In order to fully calibrate the electronics you need to repeat

previous step for all drivers.

Properly calibrated stepper motor driver:

for motor axes X, Y, Z - 0.9 V

the extruder motor - 0.9 - 1.1 V

Disconnect the USB cable and power from electronics.

Electronics Calibration 120

 20
IMPORTING SLIC3R PROFILES

20.1 Go to website:

http://slic3r.org/

and download Slic3r software for your operating platform (windows / iOS / linux).

Then download our Slic3r Config:

www.gadgets3d.com/slic3r/RRG3D.zip

and unpack it (windows x86 & x64).

Instruction for Windows 8

263

20.2 Run app slic3r.exe, window will pop-up.

Importing Slic3r profiles 121

 20

264 265

20.3 Go to File>Load Config.

266

20.4 Go to destination folder and find already downloaded config file

then open it.

Importing Slic3r profiles 122

 20

267

20.5 Config should be loaded within seconds. Your printer is ready to

go, load some 3D models and have fun.

Importing Slic3r profiles 123