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prusa i3 XL aluminum frame w/ aluminum gantry

by thainfamousnate, published

prusa i3 XL aluminum frame w/ aluminum gantry by thainfamousnate Apr 15, 2013


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this is a sneek peek of the aluminum gantry and a larger aluminum version of the i3 i've dubbed i3XL. ive been working on to replace the plastic parts and smooth rods that make up the gantry with v groove bearings and a double beveled edge. the model pictured is designed for a 300x300 custom heated bed and 2 j head extruders( hopefully prusa hot ends if they are available soon enough). once i cnc cut it and make sure it works i'll upload the files.
note: the only printed parts are the extruder parts and bed bearing holders. this design uses the same aluminum upgrades from my i3 aluminum frame.

i've been busy so i haven't had time or money to start building this, but my friend tony is thinking of it. i've included the dxf of it, its basically stretched 4" in every axis. he is using it with a dremel in place of the hot end to make a small cnc out of it. Repetier has CNC Settings in addition to 3d printing settings!!!!!!

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I plan on building one and have access to a cnc when do you think you will be finished with his project?

my friend is building this one, i havent talked to him about it in a while. he did say that the frame fits together perfectly though, just make sure you have the right material (listed below - .25" ALU)

thanks man! i would highly recommend 1/4" aluminum if you can outsource the cutting cheaply. if you cant i would recommend polycarbonate, but i dont know if that cuts too cleanly or is rigid enough, my friend has tried cutting it and it leaves nasty edges, he uses a co2 laser though. the acrylic will cut cleanly but i know it flexes very easily, even the polycarbonate flexes slightly, i cncd an original frame (non-XL i3) for a friend out of 1/4" polycarbonate and it does flex a little, but the back braces and chassis make it a little more rigid by locking it in. if you were to use acrylic or poly i wouldnt suggest cranking your speeds up too high. the parts on the right are out of 1/8" material, ignore the big parts on the right for the gantry, the printed parts work well, it was just something i was experimenting with. the frame is the exact frame from the original i3 (non-XL) just stretched 4" on all axises. the biggest thing i would think about is that the slots for the frame and other parts to interlock are designed for material no thicker than .25" with a .002 tolerance ( they are .2520" wide). i dont have plans to build one, but my buddy is slowly building one with a dremel on the gantry. he has verified that it went together perfectly with 1/4" Aluminum and i have not modified it since the initial upload, so it fits together well! definitely keep me updated as i am not building one just documenting it.

Hi, this is a very interesting approach. I already got hooked by your i3 variant and now the big one. Thank you so much for sharing it. I'm currently planning to build my second FDM printer. I have a 20W laser cutter so I will try to cut the frame in 6mm acryl. Do you think the build could be stable enough. The parts on the right side are for a 3mm sheet, is that correct? Have you already made updates to this design since you uploaded it last time or have input on what you eventually plan to improve? It would be great to work on the same basis for the common development of your XL.