[SAFETY DISCLAIMER FOR ANYONE READING THIS:
Mains power is really dangerous and potentially deadly. There's a whole bunch of potential risks, including shock hazard and fire hazard. Make sure you're qualified enough for the task, and in case you aren't, look for a good electrician. Also make sure the place wherever you test stuff is protected enough (i.e. breakers, RCDs and decent grounding). Check local regulations regarding electric equipments and safety].
NOTE: If you like this project and want it to become better and wider, please consider tipping the channel. Changing dimensions for every size, extrusion section, and even stepper size is very time consuming. Designing more different mounts for different extruder and/or hotend assembly is also such an endless task. My current workload (since we all have life beyond here :P) doesn't allow me to allocate as much time as desired on these tasks. I'd also like to spend some time learning parametric stuff so I can make it semi-automatic and more adaptable. Maybe even linked to an excel sheet (i.e. BOM). That would be awesome. That's why I'll gladly accept every piece of shared knowledge,datasheets, and also virtual pints, which will help me to cool down both my brain and PC.
GANTRY RECOMMENDED THICKNESS
X travel 300 -> 4mm (tested myself)
X travel 400 -> 5mm (4.83mm for same stiffness than mine)
X travel 500 -> 6mm (5.67mm for same stiffness than mine)
General case (for gantry):
th(min) = 4mm * (X travel+180) / 480
REST OF THE PIECES RECOMMENDED THICKNESS
4mm unless you're going reaaaaally huge (where Nema 17 wouldn't be powerful enough anyway) :)
UPDATES 8th June 2019
Changed the name because it could be misleading.
This printer has literally nothing to do with HEVO aside from being a CoreXY made of extrusions, like maaaaany other designs.
Measures are not compatible, and none of the HEVO pieces is used.
The structure is completely different, and so is the motion system.
However, a HEVO could be turned into this design with some custom made laser cut pieces for some extra stiffness.
Same can be said about original Hypercube.
UPDATES 5th May 2019
I updated the DXF files for 6030 laser cut general pieces. Now anyone should be able to get all the metal pieces for any 4020/6030 with Xtravel 300/400/500 and Ytravel 300/400/500.
UPDATES 10th April 2019
I updated the DXF files for those pieces for 4020 version which don't depend on X/Y/ZTravel (i.e. the whole pulley assembly, gantry "lids" and Z motor mounts). I'll upload something similar for 6030 asap.
UPDATES 9th Aprill 2019
I changed the bed frame to a separate file to make customization easier. Other than that the pieces remain the same. It's available for YTravel 300,400,500. XTravel is not relevant for this, note you can mix different XTravel and YTravel.
UPDATES 7th April 2019
I changed the gantry to a wider one because the original which I had cut is only meant for pancake motors and I saw on the painful way ($$) how weak those motors are. I deleted most of the documents related to it (even STL and STP) so it's not misleading anymore.
Will reupload them over these weeks. Sorry for the inconvenience.
I just remade the gantry (both 4020 and 3030) for Xtravel=300,400,500
Will convert to .DXF and upload them here separately asap.
Also have to upload laser cut pieces for both 6030 and 4020 since the gantry is not part of those files anymore in order to allow easier customization and flexibility.
UPDATES 16th Nov 2018
-A mistake was spotted on 6030 DXF files for laser cut files. The version uploaded today has that mistake fixed.
UPDATES 22nd Oct 2018
-Since most Titan pancake motors are not powerful enough, many people have to use the standard one (38mm long from the flange). Now the spacers are 44mm long instead of 32.
That means the gantry can be wider, so I made it 30mm wide instead of 24 to improve strength though it will become slightly heavier, but not much of an issue. This should also increase a little bit torsional stiffness.
-An error regarding pulley holes position has been spotted on 3030 gantries. They have been fixed and reuploaded today, also made wider, as I said before. Contact me in case you have downloaded 3030 pieces before 22nd Oct 2018.
UPDATES 1st Oct 2018
-Uploaded new DXFs. There are no changes, the pieces have only been moved to separate DXFs. Remember that I didn't test 6030 assembly, nor I'm going to test it myself. Input is welcome, though.
-The mount for Titan extruder + E3D hotend is now a different file, so it should be easier for those who use something different.
-DZSM mod (Dual Z Single Motor) is under development. I'll soon release the STL pieces to hold the thrust (axial) bearings (10x18x5.5mm). The DXF are already released and no changes are expected. It's meant for 1140 mm closed GT2 6mm wide belt and 40T GT2 pulleys. I'll test this myself over the next weeks.
-A mount for Titan Aero extruder+hotend is being developed. I don't intend to test this one myself.
-Titan Mount should also work with Bondtech BMG, but I haven't tested it myself. You can print the piece (4mm thick) in case you want to try it. Drop me a line if it is compatible :)
UPDATES 29th Sept 2018
-Uploaded current version of the DXF for laser cutting. I recommend 4mm thick for 300^3, for bigger build volumes increase thickness accordingly (feel free to ask about it).
-There's a DXF for 4020, and another one for 6030. I got 4020 pieces cut for my own printer, as you can see in the pictures. The other one is not tested, bear that in mind if you go ahead.
-For the reason stated above, I've no full control about whether or not certain stuff for 6030 extrusions is easy to find.
-Made mounting holes a bit smaller after my own laser cutting experience.
UPDATES 29th June 2018
-Uploaded mount for BLTouch probe (Titan extruder). It's not tested, so some input would be welcome.
-Uploaded a new laser cut gantry version (DXF), 100mm shorter, for 200x200 heated beds, for both 4020 and 3030 extrusions.
-Corrected some mistakes spotted in the pieces on top of gantry.
UPDATES 22nd June 2018
-Laser cut pieces for both 4020 and 3030 extrusions have been changed, in order to change the position of XY belts along X axis.
-I'm also working on better mounts for XY endstops.
HYPERCUBE EVOLUTION MGN REWORK AVZ [thinking of a better name]
This is my rework for Hypercube Evolution (HEVO). As you can see, XY mechanism has been heavily modified and round bars have been replaced by MGN linear rails (like Hiwin ones).
Motor and Idler Mounts have been changed to a 2D like design, in order that they can be CNC machined or laser cut from a 4mm thick aluminum plate.
I chose Dual-Z axis setup for better stiffness. Tr10 Leadscrews, and LMK12UU flanged linear bearings for Z axis.
I also changed extrusions from 3030 to 4020, because they're slightly lighter, slightly cheaper, and when it comes to bending, they offer +60% better inertia than 3030 if oriented properly. Extrusions length has been increased in order to keep the same printing volume while keeping everything inside the cube, so it would be easier to have it enclosed...
Feel free to ask questions and/or provide feedback :)