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Note - there will be no further updates to this page. Any further updates will be on the FB2020 Github page - https://github.com/AxMod3DPrint/FB2020
This is a rework of the Fusebox 2020 by Culain, which in turn is a rework of the Original Fusebox by AlexY. However at this point, there's not really much left of the mechanical workings of the original design. All the Carriage parts now have push fit bearings opposed to being cable tied. The X and Y Axis have been re-designed from the ground up to allow push fitting of the bearings. The Z axis is still mostly Culain's design, but has been modified to allow push fitting of bearings.
The Ethos of the Fusebox was to keep parts pricing low, which at the beginning of this project, was the same aim, however, it is now to improve the FB2020 to a point where it's pretty much it's fool proof and highly reliable. I want it to the point where anyone with a set of Allen keys can put it together. I'm happy with the frame rigidity, yes, it's not as rigid as it could be, but I still want to try to keep costs down where possible, by using printed plastic parts this helps a little. I've added a list of upcoming changes below.
All files should be orientated correctly for printing. Any file marked Culain is an original file from Culain's design and no physical changes apart from mirroring and orientating correctly have been made.
All bolt, rod and hot end holes on the STLS for the Carriage and Carriers have a 0.4mm tolerance. If you need less or more, grab the SCAD files. There is a setting in there to change it.
The best way I have found is to loosen off the motors so they are on the end of the bolts in the Y direction. Pull the belts as taught as you can manually then tighten the motors back up to bring the belts to full tension. I'm working on a better tensioning system currently.
https://youtu.be/WNDfNemOfFM - Gayer-Anderson Cat in Whiter Generic PLA at 80mm/s at 0.1mm layer height.
https://youtu.be/yOhGpVYnDCI - Aztec Chief in ColorFabb NGEN at 80mm/s at 0.28 Layer Height
https://youtu.be/bmPf83OeyGA - Printing the Rigid coupler in ColorFabb NGEN at 80mm/s & 150mm/s Travel - retraction settings were being worked on, so the print is a little stringy..
https://youtu.be/XaOWR-UzrOI- 2nd Print - #3DBenchy Timelapse.
Migbot Prusa i3
Print as orientated, Support needed for Extruder Carriage, Carriers, Idlers, layer fan assembly and right side idler rod mount.
All parts need to be printed at 70% infill for strength with the exception of the Bowden tube clips at 100% infill and RAMPS mount and Z endstop mount at 15-20%
Bed Mounts uploaded
Rigid coupler added
Rigid Coupler design slimmed down (damn my spacial awareness), Carriage modified to stiffen up clamp for E3D
Carriage modified to allow for printing without supports, clamp shortened by 2mm
Bed Holder bearing holes enlarged by 0.3mm to allow easier fitting of the bearings and to allow for printing variances. Carriage SCAD file & RAMPS mount uploaded
Modified Z Leadscrew Holder & Z Endstop mount - original had holes too close for T nuts.
Added quick and dirty spool clamp. Needs M8 Threaded rod and 2 13mm nuts
Added carriers for Y axis. Designed to work with the new X Carriage as the belt clips will not align with the existing Carriers. Uploaded all parts. Carriers printed and found to be a little tight on the bearings and not enough space to guide the belts. Modified to guide the belts, left carrier now has endstop lug to hit the Y endstop.
Reinforced Y rod carriers, fed up of them breaking. Carrier near right hand idler will need support. Printed and modified again (removed cap our rail mounts) to allow for irregular length rods. Mine are ~1mm out. Carriers modified to allow the same. Bill of Materials added
Carriage modified, reinforcing belt clips fixed bearing alignment with carriers. Bed Carrier extrusion slots widened by 0.4mm. Far too tight to fit the bed extrusions effectively.
Left and Right Carriers now have inbuilt support on the clamp slot, this was done due to printing issues. Extruder Carriage now has slightly thicker and taller belt clips. Spool holder nut slot enlarged due to being too small. Short version of the Z axis Carriers added, allows use of LM8LUUs. Removed rigid coupler as there's a slight Z wobble. Leadscrew nut holder central hole increased in size as too small. All files refreshed and have been numbered with the amount to print. Lost spool holder SCAD file in a shift-delete accident.. :(. Files marked Culain are originals from Culain's design. The bed holders have just been re-orientated and mirrored, no other physical changes have been made. After a conversation over on the RepRap forums, the option to add an endstop to the Extruder Carriage has been added. You will need a standard Omron style micro-switch and 2x 14mm M2 bolts, these should screw directly into the Carriage but can alst use nuts on the other side. This allows one bundle of cables and tubing to be moving over having the endstop moving on the Y Axis and the Bowden tube moving on the Carriage. Derped on hole placement for Omron Microswitch, corrected. Moved Y endstop bumper down, wouldn't make proper contact. Uploaded SCAD files for Carriers and Spool Clamp, didn't delete it after all.
Added Left carrier with no endstop mount to complement the move of the endstop to the carriage - this will print without support, STL & SCAD file uploaded for this. Updated RAMPS mount, Derped putting stand-offs on the wrong side. Moved the RAMPS in by 5mm
Front Bed Holders reworked as they did not fit. Corner Idlers strengthened, the top bearing holder was constantly breaking on the right side. Z Endstop mount lengthened due to not enough travel. Renamed FB2020 due to very little being left of the original design and is now in it's own right a different printer. Added Bowden Tube wire clips, source added.
Z Endstop reworked, now uses an Omron-style limit switch and bumps off of the Z Carrier. Fron Bed Tie added to stiffen up bed, (this can be changed out for another 147mm Extrusion piece and 2 more corner brackets. Front bed holders tweaked to bring holes in line with the Z Axis bed holders. Added a new Rigid Coupler for the Z Axis, clamps concentrically with 2x M3x16 Bolts. Z Leadscrew length shortened to 250mm as 300mm fouls the Extruder carriage
Carriage - Belt clip notches moved to opposite side and E3D mount widened to allow easy fitting - SCAD file modified to allow extra diameter for printing. A twist in the Belts on the outer long runs is now needed. This makes the belt run on the smooth side for all the idlers and increases print quality.
Idlers - Re-orientated for strength layers are now in the opposite direction of the belt tension, now need printing with support.
Bowden tube wire clips added to keep Bowden tube and hot end wiring together and tidy
Bowden Clip added to keep E3D collet up and stop filament backlash.
Compact Direct Drive Extruder added - modified for a 6mm Pneumatic Coupler and an E3D HobbGoblin Drive Gear
Updated BOM to reflect changes.
Firmware updated to Marlin 1.1 RC4. Enabled Mesh Bed Levelling and PID on the Bed. X0 Y0 is the Front left of the printer, Y homes to Max.
Changed layer fan for spinorkit's 2 pronged setup, which has been shortened to allow clearance of the leadscrew, this layer fan assembly is a lot more effective as it cools from two sides. As such this needed a new Active cooling duct for the E3D hot end, to mount the layer fan off of, this cooling duct clamps with 2 22mm M3 bolts and will not move once clamped.
Description updated and planned changes added.
Bed converted to 3 point levelling, new brackets added, use front bed tie for the middle of the bed to stiffen. Longer lengths for bed reduced to 235mm.
Carriage updated. Added extra room for cabling from hot end & flattened off clamp on carriage. This should allow for easier belt fitting and will retain the nut on the clamp on the carriage. Several minor changes including centring up of the hot end. Note the STLS are uploaded with 0.4mm tolerance as my Prusas print tight. If you need less grab the SCAD file.
Carriage extended by 5mm to allow further easier fitting of belts and hot end. There's roughly 4.5mm either side of the bed so there is room for further extension if needed.
Bill of Materials
2020 Extrusion lengths
4 x 345+ mm (Frame, vertical)
6 x 380 mm (Frame, X Axis + diagonal)
2 x 340 mm (Frame, Y Axis top)
2 x 300 mm (Frame, Y Axis bottom)
2 x 235 mm (Bed, Z Axis)
1 x 147 mm (Bed, middle) - if using printed tie or 2 x 147mm if not.
8x 625ZZ - Idlers
1x 608ZZ - Extruder
4x Nema17 Stepper Motor (40 Ncm min)
1x RAMPS 1.4
1x Arduino Mega
4x A4988 or 4x DRV8825 Stepper Drivers
1x Set RAMPS Connection wires
1x MK2B PCB Heater
1x 100k 4.7k Pullup Thermistor - heatbed
1x E3D v6 with Bowden kit
1 Meter 14 AWG wire (PSU to RAMPS)
1 Meter 16 AWG wire (Bed to RAMPS)
1x 12v LED PSU
1 x Mains cable and Plug
3x Makerbot-style Mechanical Endstops or 1x Makerbot-style Mechanical Endstops & 2 Omron or similar Micro Limit switch.
1x Reprap Smart Controller or 1x SDRAMPS
2-3 Meters LED Strip (https://www.fasttech.com/products/1211/10000732/2174203)
1x 250mm long 8mm Leadscrew and Nut
2x 300mm 8mm Smooth Rod
2x 340 8mm Smooth Rod
2x 300 12mm Smooth Rod
1x 100mm Smooth Rod or 1x100mm M8 Rod & 2x M8 Nuts - Spool holder
~150 x M4x8mm Bolts - 6mm will work but can be a little annoying with T-Nuts
100x T- Nut - Misumi
6x M4 Printed T-Nut - STL in files - not my design, can't find the Thing to attribute as didn't collect it. - PSU clamp (to be uploaded after testing), extruder, Spool holder
10-15 x M4 Nut
2x M5x25 Bolts - Y Idlers
10x M5x10 Bolts - Frame Idlers, Extruder
18x M3x10 or M3x8 Bolts - Attaching Steppers/Leadscrew
5-10x M3 Nuts
Mix of 10-15 M3x16 & M3x22 Bolts
4x Bed Springs
4x Thumb Nut
1x Glass or Aluminium plate
3m GT2 Timing belt
2x GT2 20 tooth Timing pulley
1x 40mm 12v Fan
1x E3D HobbGoblin Drive gear
4x 15mm x M2 bolts - Limit switch on Extruder Carriage and Z Endstop
1x 5mm to 8mm Flex or Rigid coupler
2x M2 Nut
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FB2020 CoreXY by AxMod3DPrint is licensed under the Creative Commons - Attribution - Non-Commercial license.
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