01 Background

The Mendel90 3D-Printer was built at Worcester Polytechnic Institute in 2014 for MAST (Marine Academy of Science and Technology) high school. This project involved laser cutting an acrylic frame, 3D printing brackets and components using a Prusa i2, assembling stepper motors and hot end, wiring the power supply, and calibrating for first prints. The complete build log is documented below with 46 photos.

02 Photos

Complete build log from start to finish.

Laser Cutting the Acrylic for High Resolution Frame

Frame Successfully Cut

Printing out Right Angle Brackets

Pronterface Showing Toolpath Instructions for 3D Printer

X-Axis Idler — Clean First Layer

X-Idler Nearly Finished Printing in Beautiful Quality

X-Idler Up Close in Proper Lighting

Linear Bearings Pressed into the Plastic

Various Components Printed on the Prusa i2

Working on the Wade's Extruder Block

Printing out the X-Carriage Which Will Support the Extruder Block

Linear Bearings Secured onto the X-Carriage

X-Motor Mount Assembled with Linear Bearings and Stepper Motor

Heated Bed (12V 11A) over Aluminum Foil Tape to Reflect Infrared Radiation — Cardboard Insulator Used as Well

Heated Bed with Aluminum Foil Insulator

Underside of Print-Bed with Bearings

Brass Nozzle and Threaded Pipe Assembly

Creating the Ceramic Heat Core with Crimps and Covering in Layers of Ceramic Paste (To Be Cured in an Oven)

Creating the Ceramic Heat Core

Printing Filament Spool Holders

Testing Component Alignment on MDF

Orthogonal Acrylic Frame Squared Away — Y-Axis Secured and X-Axis Attached by Stainless Steel Round Bar

Frame Squared — Y and X Axes Attached

Heated Bed Removed to Tension Y-Axis GT2 Belts

Mendel90 Construction So Far — Power Supply on Order

Kapton Polyimide Tape Used to Cover the Glass Panels — When Heated, Adheres Well to Other Polymers (PLA / ABS)

Kapton Tape on Glass Print Bed

Strands of Ribbon Wire Connected to Support Higher Current (1.1A / Cable) — Ribbon Cable Used for Clean Rolling Action

Ribbon Wire for Higher Current Capacity

Hot End in PEEK, Secured to Extruder

Most of the Ribbon Cable Wiring Completed

3D Printed Serial Connector for Extruder

Power Supply Mounted Flush to Acrylic

Universal IEC Connectors so the Printer May Be Unplugged — Socket is Fuse Protected for Safety

Fuse-Protected IEC Connectors

3D Printed IEC Cage Mounted onto the Power Supply

Heat Shrink Ring Terminals

Enclosure All Sealed Up, Testing Fit and Voltage

The Mendel90 on the Left, and the Prusa i2 on the Right

Prusa i2 and Mendel90, Mid Construction

Serial Quick-Connects on Stepper Motor

Female Connector, Disconnected

Connectors Combined — Ribbon Cable Rolling

Arduino on Pololu Breakout Board

Preparing the Printer for First Calibration Prints

Plastic Running Through the Extruder Heating Up

Ready for First Print

First Print — Left-Facing Owl

Action Shot! Printer is Printing the Owl

Owl Printed — Great Overhangs, No Fan

Preparing Print Number 2 — Squirrel!

Success!