This is a complete set of printable corners for the RapMan 3.x printer from Bits From Bytes.
They may be used as stronger replacements for the (very fragile) standard acrylic corners, and are designed to be installed without having to take the whole machine apart. Most corners now require only 3 easily-accessible bolts (down from 8), and importantly, no more fiddly grub screws :)
Apart from making the whole machine stronger, the Z motor corner now includes a mechanism to easily and accurately adjust the tension on the Z belt. This is now a one-handed operation, not three-handed!
The Y motor corner requires 2 files (top_backleft.stl, ymotor_clip.stl) whilst the Z motor corner requires 4 files (bottom_frontrightbackleft.stl, zmotor*.stl) All other corners are each 1 file only; even the top corners, as the bearing holders are now all integrated.
I have endurance-tested these parts with a 24-hour non-stop print and everything is still running smoothly. If I find any weaknesses, I will update the STLs.
NB: Some of the green STL auto-renders displayed left and below are mirrored; they are however correct once you download them (tested in both BFB Axon and MiniMagics)
Update 2015-01-16: Uploaded v2 of some parts that had normals inverted and didn't play nice with some slicing software
NEW Z washer STL uploaded, re-added the hole that was missing. (how did I miss this??)
The vast majority of these parts are designed to be printed on almost any 3D FDM printer with no supports, using standard ABS and no heated beds or other fancy attachments. (Do not use PLA, it is too soft.) The parts in the photos were printed with a Rapman 3.1.1, using G-code generated by BFB Axon v1.11. After printing, I recommend cleaning out the holes with correspondingly-sized drill bits (3mm, 5mm, 8mm, 12mm)
Only the Y and Z motor corners require further detail here:
Y motor - Note #1: top_backleft.stl requires support to be printed. Simply use standard Axon settings but turn support on (I used cross-hatch 10% 'everywhere', perhaps 'exterior only' is better)
Y motor - Note #2: When fitting M5 bolts through ymotor_clip.stl, you only need to tighten the bolts until the gap closes to ~0.5mm (see photo)
Y motor - Note #3: The photos show a 3mm-thick arm holding the Y limit switch; this has been upgraded to 6mm-thick in the STL.
Z motor - Note #1: To attach the carriage to the plate, you will need a 70x8mm smooth rod from one of the top front corners, so print and replace those first.
Z motor - Note #2: The plate measures 122mm in its longest dimension at the base, so it will warp a little during printing. Don't worry about this as the warp works to our advantage once the Z motor is mounted to it.
Z motor - Note #3: I highly recommend replacing the Z pulley as the standard one is very fragile and either breaks or comes loose quickly. I used the design near the bottom of this page: http://www.bitsfrombytes.com/wiki/index.php?title=Spare_parts