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Instruction manual

Felix 1.0 revision E, 3d printer-kit

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This document contains proprietary information that is protected by copyright. No part of this document may be photocopied, reproduced, or translated
to another language without the prior written consent of FELIXrobotics.

FelixRobotics

Hoogstraat 421H
5654NE Eindhoven
Netherlands

Summary of Contents for Felix 1.0

Page 1: ...ht Information This document contains proprietary information that is protected by copyright No part of this document may be photocopied reproduced or translated to another language without the prior...

Page 2: ...Module 5 Table time 1 2 hours 25 10 Module 6 Y axis time 10 30min 27 11 Module 7 Electronics time 2 4hrs 31 11 1 Mount the powersupply 32 11 2 Connect allpossiblewiresto electronicsboard 33 11 3 Conne...

Page 3: ...info felixprinters com www felixprinters com Page 3of 65 14 Calibration oftable 5 15mins 42 15 It s time for printing 15 30mins 53 16 FAQ 55 17 BOMFelix 1 0Revision D 58...

Page 4: ...lts and nuts is required Further to not bloat the manual a picture of each part is only displayed in the complete BOM of the printer This can be found in the Supplement of the document Before starting...

Page 5: ...x440inclwork 1 40x40protective caps 4 80x40protective caps 1 frame connector set 6 handle inclprotective cap 1 hexsockethead boltM6x1 2 t slot nut 8STM6 2 t slot nut 8STM4 22 dampningfeet 6 strip for...

Page 6: ...beam4 onto beam 1 Slide beam 4 in position On the side of beam 1 where the hex key is positioned there are two drilled holes Tighten the frameconnectors by sticking the hex key through the holes Do n...

Page 7: ...it Take beam 2 again and screw the frame connector on it s far end Then slid it on beam 3 as indicated on the picture Next try toslide it also on beam 4 Thighten the screws again not too tight Now it...

Page 8: ...eams are aligned and leveled it is time to firmly tighten the frameconnectors Get the protective caps and mount them carefully with a hammer Put the damping foots underneath the frame neartheedge The...

Page 9: ...e z axis spindle by means of a set screw It needs to be 15mm high and approx 1 mm deep This is not required for the y axis motor BOM Z axis Partdescription Amount Igus GmbH_NS 01 80 rail 1 Igus GmbH_N...

Page 10: ...he big bearing inside the z spindle holder It should be a tight fit and it can be pushed in Mount the z axis motor IMPORTANT the cables must be oriented according to the picture Get the frame and put...

Page 11: ...herwise the bolt head will touch the slider Also important is that the rail should touch the z motor bracket The z spindle mount should also touch the rail Use a small washer and an M4x16 bolt Mount t...

Page 12: ...drill Just a little material should be removed in order to make a bolt go in there Mount the big part onto the z axis carrier with small washers and m4x12 bolts Tip put the bolts in place with the su...

Page 13: ...do the same with the m4 self locking nuts When approximately in place try to keep the nut into place with your finger Then with the other hand tighten the bolt with an allen key When the thread of the...

Page 14: ...M4x16 bolt Let the tip of the bolt touch the flange as indicated in the picture Mount the pulley upside down onto the motor axis The distance from the bottom of the pulley to the motor housing should...

Page 15: ...r is tocompensatefor anuneven surface of the m8nut Ifyoumount it too the curvedwasherwill not help anymore Put the printeruprightand fixthe m3 setscrew inthe coupling very gently on the motor axis You...

Page 16: ...ting it all together We start with the extruder belt clamp tensioner Use m4x30 bolts and self locking M4 nuts For the top bolt also use asmall washer Get the extruder arm Mount an M4x20bolt From left...

Page 17: ...the bronze insert_piece should ideally not be filed Mount the motor with insertpiece onto the extru_base_pt2 with 4 m3x8 countersunk bolts IMPORTANT the orientation of the motor should be the same as...

Page 18: ...including one airduct For the fan with airduct use M4x25 bolts including one small washer For the other fan useM4x20 bolts Usesmall washers When done it should look like the picture above Before comb...

Page 19: ...stic part medium washer plasticpart small washer m4self prevailing nut Mount the hot end Move it from underneath the extruder base then slide it onto the slotted hole Finally fix the hot end with the...

Page 20: ...rge washers and 3 crinkled washers When you have it in place screw the 2 bolts up to put very little to no tension on the arm Very little because when the filament comes in the arm will be tensioned F...

Page 21: ...ema 17 1 bearing624 1 optosensor 1 Get the x axis motor bracket mount the optosensor don t forget to put the double sided tape underneath Then mount with the bronze screws Mount it to the frame by ins...

Page 22: ...ry to assemble the x axis Use the holes at the far ends of the rail and the middle one Fixthe x axis rail Thedistance between thehighlightedfaces shouldbe approx2mm Push the extruder onto the x axis s...

Page 23: ...parts ontotheframe Beforedoingthis cut the belt atonepoint and guide theendover the bearing as indicated above Thepart displayed in the picture above is froman older revision but instruction are simi...

Page 24: ...cm at oneend On the otherend leave the remainderof the long belt Pull on both belt ends by hand to tension the belt while keeping the belt tensioned thighten close the clamp to fix the belt and keep...

Page 25: ...kitheat resistant 1 Coolingpaste 1 Take the plate Note that there are three 4mm holes which are reserved for the M4x30 countersunk bolts Further more there are eight 3mm holes which are reserved for t...

Page 26: ...re will go from the bed to the electronics Don t waste too many because the rest of the wire goes from the table to theelectronics Strip all wire ends twist the stripped end and guide it through the h...

Page 27: ...01 40 rail 2 Igus GmbH_NW 02 cart 2 20x10_profile 1 t_slot_nut_5 1 Be sure you have the rail and slider combination with both y axis on it Use the M4x16 bolts to mount the printed parts to the aluminu...

Page 28: ...the amount of washers ond the picture above On the 3 M4 countersunk bolts of the table make sure that on top of the already placed rings from the previous module there are 6 large M4 washers and 5 cur...

Page 29: ...small allen key for that If you have misplaced the belt or you want to remove it on top of the bracket is a small hole which can be used to push out the belt with a small allen key Guide the belt ove...

Page 30: ...ng bolt See picture above The belt should be tensioned when the distance between the parts is approx 1 to 2 mm Check if you applied enough tension by pushing the belt as displayed above It should feel...

Page 31: ...w will guide you step by step to match theschematics above NOTE It is important that the cables are placed as neatly as possible Placing the wires in a messy way can lead to EMC problems which than ca...

Page 32: ...description Amount powersupply_bracket_pt5 1 powersupply_bracket_pt4 1 ramps_case_pt1_v2 1 ramps_case_pt2_v2 1 ramps_support 2 RAMPS arduino steppers fully assembled 1 mini ATX seasonic 1 Power CableN...

Page 33: ...of labeling isto fold a piece oftape around near the connectors and write something onit with apermanent marker The threewired cables arefor the opto sensors the4 wiredcables are for the motors andthe...

Page 34: ...ht 2x Hot end powerresistor cables airduct fan black airduct fan red 2x heated bed powerresistor cables 12V yellow COM black 12V yellow COM black The wire colors of the hot end and heated bed can be d...

Page 35: ...stor cable Make sure the loop is intermitted at the top part of the z axis carrier Mount it there with a cable tie Then make the second loop from the z axis carrier to the vertical beam The second loo...

Page 36: ...Easiest isto startwith the x axismotor From both ends remove excessive pieces of cable IMPORTANT do not throw away the cut off pieces of cable because it has to be used for later Strip the ends recomm...

Page 37: ...rs The power resistor wiresare long enough to directly connect to the ramps electronics Please check the schematics 10 6 2 The3 fans 1 The fan which is connected to the air duct underneath the extrude...

Page 38: ...dled cable to let it through the opening The cables must be pushed flat becausethe lid of the box must be placed on there Get the heatsinks and put the self adhesive conductive tape on it Place the he...

Page 39: ...Page 39of 65 Cut of a piece of frame strip to hide thecables that run through the frame Finally the front view of the printer should look like this Congratulations you are done with the electronics pa...

Page 40: ...with a shining through color the opto sensors of the axes might not work To make them work you can put one of the following thingson the switching vanes a Non shining through tape on the flange b Tipp...

Page 41: ...ging strokes of plastic around the edges Then afterwards clean the surface with detergent Supplied with the kit is kapton tape After several tests with different kinds of tape we atFelixPrinters recom...

Page 42: ...he table in y direction 6 Move the table a little closer to the hot end and repeat the previous step Calibration in x direction 7 Move the table to the middle of its movement range 8 Move the X axis c...

Page 43: ...rrect operation of your Felix printer Steps to upload new firmware to the FelixPrinter 1 Make sure the power cable of thepower supply is disconnected 2 Plug in the USB cable into the RAMPS electronics...

Page 44: ...orrect platform Tools Board Arduino Mega ATmega1280 Select the correct Serial Port which you ve noted earlier Tools Serial Port COM Extract the downloaded FelixPrinter firmware tosome folder Open this...

Page 45: ...e upload 5 Now it is time to install thesoftwarerequired to convert your CAD files to the G code and control the printer Again go to the FelixPrinters website and do the following a Download and insta...

Page 46: ...system settings iv Click Environment variables v Scroll on the lower part of the window till you see Path Click once on the line and then click Edit vi Add the directory name of Python don t forget to...

Page 47: ...tier Host fromwww felixprinters com 2 Extract the zipfile The following files directories shouldappear Choose the setup exe file toinstall Repetier host Select the two directories and copy them into t...

Page 48: ...felixprinters com www felixprinters com Page 48of 65 Match all the settings fromthetabs The com13inthepictures isprobably differentfor your situation The com port is obtained in previous steps ofthema...

Page 49: ...ting Go toSlicerand presssetup Match all the fields inthepicturebelow and afterwardspress OK 6 Press theConfigure button The slicing settings must come up Checkunder profile selection ifthereare sever...

Page 50: ...ress the Add STL file Then navigate to the installation folder of repetierhost and choose the _40x10 STLfile fromthe subfolder displayed inthepicturebelow 9 Slice this file and prepare itto print Pres...

Page 51: ...is time to calibrate the z axisheight with the z axis limitswitch vane 1 Make sure if you have a shining through color printed parts for the printer to apply the tape tipexx to the limit switch vanes...

Page 52: ...th The axis will only move in positive direction if the Home X button is not pressed Press Home Y move the yaxis back and forth Press Home Z The distance between the table and hot end is probably too...

Page 53: ...sion start with a low temperature Then go up slightly When the temperature is too high you might hear some pops and sisses coming from the hot end When the temperature is too low the extruder motor wi...

Page 54: ...led out when hot from both sides A tutorial for this is available on the forum on the website When changing different kind of filament it can be done in 2 ways 1 Just cut the old part just above theex...

Page 55: ...y smallobjects try to print at low speedor tryto print moreat once thisgives toprevious printed layers timeto cool down a bit Heated bed The first layerwhich is in contact with theheatedbed isthefound...

Page 56: ...tightened 1 Pulley s arenottightened enough 2 Belt tension is not high enough Hot end Checkthat the hot end is fixed inthe extruder carriage If not the printswill comeoutugly 15 3 Software High print...

Page 57: ...little and see what happens Too much will give some twitching of the motor when that happens turn the screwbacka little For the X axis Tension the belt properly Too muchtension will give high frequen...

Page 58: ...ISO 4762 M4 x16 16N 20 ISO 4762 M4 x20 20N 15 ISO 4762 M4 x25 25N 9 ISO 4762 M4 x30 20N 5 ISO 10642 M4 x30 30N Countersunk 4 ISO 4762 M4 x40 20N 2 Washer ISO 7093 4 medium washer 18 Washer ISO 7089 4...

Page 59: ...otor bracket_v5 1 x axis belt mount_v4 2 y stage bracket pt1_v5 1 y stage bracket pt2_v4 1 y stage bracket pt4_v3 1 z spindelmount bottom v3 1 z_axis_carrier_pt1_v3 1 z_axis_carrier_pt2_v5 1 z axis mo...

Page 60: ...com www felixprinters com Page 60of 65 Extru_base_pt3 1 Extru_belt_clamp_v3 1 Extru_arm_v2 1 Extru_airduct_v2 1 powersupply_bracket_pt5 1 powersupply_bracket_pt4 1 ramps_case_pt1_v2 1 ramps_case_pt2_v...

Page 61: ...rs fully assembled 1 Fan 40x40x10mm 3 mini ATX seasonic powersupply 1 Power Cable NL optional 1 Power Cable USA optional 1 Power Cable Australian optional 1 Power Cable British optional 1 optosensor 3...

Page 62: ...2m for heatbed and hot end 2 Mechanics Igus GmbH_NS 01 40 rail 2 Igus GmbH_NW 02 cart 2 Igus GmbH_NS 01 80 rail 1 Igus GmbH_NW 02 80 cart 1 pulley_motor_HTD 2 Toothbelt 1 5m 1 z spindle 1 bearing 8x2...

Page 63: ...incl 1xM8 1xD7 2 40x40x400 profile incl 3xD7 1 80x40x440 incl work 1 40x40 protective caps 4 80x40 protective caps 1 frame connector set 6 handle incl protective cap 1 hex sockethead bolt M8x16 butto...

Page 64: ...info felixprinters com www felixprinters com Page 64of 65...

Page 65: ...rts Hot_End_base_3mm 1 Hot_End_peek_isolation_3_v2 1 hot_end_heated_nozzle_3 1 table_2mm 1 Z axis coupling_v11 Others tweezers 1 tape for heated bed 1 cable ties setof 100 1 cable spiral 1 25m 1 2m ca...

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