X Gantry - OHAI - Open Hardware Assembly Instructions

Step 1 of 37

Install backside fasteners

Insert 4x m5-hex-lock-nut into the following region

Step 2 of 37

Install frontside fasteners

Insert 5x m5-hex-nut into the following region

Step 3 of 37

Prep for top camera focus

Acquire top-camera-focus-jig and connect top-camera-focus-jig to a laptop and open a native camera viewing application
Remove lens-cap from top-camera
Install the top-camera fully into the top-camera-focus-jig, plugging the USB cable into the camera module afterwards

Step 4 of 37

Inspect the image and adjust

In Photo Booth, change the selected camera to LumenPnP Top to view the camera feed from top-camera
Rotate camera lens until live view shows datum-board as focused as possible

No image for this step

Step 5 of 37

Remove Camera and Replace Cover

Remove the top-camera from top-camera-focus-jig and immediately replace lens-cap

Step 6 of 37

Install Top Camera

Install top-camera into x-gantry-back

Step 7 of 37

Install Top Light

Install top-ring-light into top-light-mount
Install top-light-mount onto back of x-gantry-back

Step 8 of 37

Secure Top Light

Secure top-light-mount in place with 2x M3x12-self-tapping-flat-head

Step 9 of 37

Prepare NEMA-17-stepper-motor for x-linear-axis

Set timing-pulley height on NEMA-17-stepper-motor shaft with x-pulley-spacer-jig
Tighten the first set-screw into the flat region found on the NEMA-17-stepper-motor shaft, before tightening the second set-screw
Tighten each set-screw to 0.5 N/M

Step 10 of 37

Install NEMA-17-stepper-motor onto x-motor-mount

Orient NEMA-17-stepper-motor onto x-motor-mount so that the motor's connector is facing the backside of the print as shown in the image
Bolt NEMA-17-stepper-motor onto x-motor-mount with 4x M3x8-bolt

Torque Spec

Tighten these bolts to 0.5 N/M

Step 11 of 37

Install XY-limit-switch-board onto x-motor-mount

Install XY-limit-switch-board onto x-motor-mount and secure it with 2x M3x8mm-self-tapping-flat-head-screw
Tighten each screw in place with the electic torque driver
If needed, clipping the ends off the pins of the right angle switch on XY-limit-switch-board helps the pcb sit flat against the print.

Step 12 of 37

Install nut into into x-idler mount

Install 1x M5-lock-nut into x-idler-mount

Step 13 of 37

Install Belt Tension Arm onto X Idler Mount

Install belt-tensioner-arm onto x-idler-mount as shown

Insert the correct direction

The acorn nut should be resting against the x-idler mount when installed correctly
Bolt belt-tensioner-arm to x-idler-mount with 1x M5x40-socket-head-bolt

Don't Overtighten

belt-tensioner-arm should be able to pivot smoothly without much resistance.

Step 14 of 37

Install alu-extrusion onto x-motor-mount

Insert alu-extrusion into x-idler-mount, using light force as necessary
Insert 2x M5-t-nut into alu-extrusion
Secure alu-extrusion in place with 2x M5x10-socket-head-bolt

Torque Spec

Tighten these bolts to 0.5 N/M

Step 15 of 37

Install M3-t-nut-bar

Inspect the M3-t-nut-bar to ensure that each hole has M3 threads

Slide M3-t-nut-bar into top-side track of alu-extrusion

Step 16 of 37

Install x-idler-mount onto alu-extrusion

Insert 2x M5-t-nut into alu-extrusion
Slide x-idler-mount onto alu-extrusion

Step 17 of 37

Secure X Gantry Spacing

Use x-gantry-spacer-jig to slide x-idler-mount onto alu-extrusion. The x-linear-axis should be sitting on x-gantry-spacer-jig snug - not overly tight - when x-idler-mount is at the correct depth
Secure x-idler-mount in place with 2x M5x10-socket-head-bolt

Note

Tighten these bolts to 0.5N/M

Step 18 of 37

Align linear-rail-525mm

Roughly position linear-rail-525mm onto top-side of alu-extrusion
Place a linear-rail-2020-alignment-jig on both ends of linear-rail-525mm. Do not cover any bolt holes with the jig
Visually center linear-rail-525mm between x-motor-mount and x-idler-mount
Slide the M3-t-nut-bar to line up with the rail's bolt hole pattern

Step 19 of 37

Load Screws for the 525mm linear rail

Starting from the x-motor-mount side, lightly snug a M3x8-bolt into every other bolt hole on linear-rail-525mm
Move the linear-rail-carriage out of the way as needed

Step 20 of 37

Attach the 525mm linear rail

Tighten the rail mounting bolts to in the sequence shown in the image, starting in the center.

Note

A torque wrench set to 0.5N/M must be used when tightening these bolts

No image for this step

Step 21 of 37

Remove the jigs and check movement

Remove the linear-rail-2020-alignment-jig from both ends of linear-rail-525mm
Slide the linear-rail-carriage back and forth a few times, checking to see that it travels smoothly and consistently

Step 22 of 37

Install GT2-belt and x-gantry-back

Using a 1.5m-long piece of GT2-belt:
- Start by running the belt through the left-side slot on x-gantry-back and leave 75mm of extra belt poking out
- Run it through the extrusion towards the x-motor-mount
- Wrap it around the timing-pulley
- Run it back through the extrusion towards the x-idler-mount
- Wrap it around the idler-pulley
- Run it back through the extrusion towards the x-motor-mount again
- Have the belt exit through the right-side slot on x-gantry-back

Step 23 of 37

Attach X gantry back to rail carriage

Slide the x-gantry-back onto the linear-rail-carriage while pulling slack out of the GT2-belt
Apply threadlocker to 4x M3x16-bolt
Tighten each bolt to 0.5 N/M. Push x-gantry-back into the linear-rail-carriage while tightening the mounting bolts to align it.

Warning

Ensure that x-gantry-back sits flush against linear-rail-carriage without any visible gaps

Step 24 of 37

Affix Belt Clamps

Use belt-clamp with 2x M5x10-bolt to clamp the left-side of the GT2-belt to the x-gantry-back
Tighten each M5x10-bolt to 0.5 N.M

Step 25 of 37

Attach other side of belt

Pull the right-side GT2-belt tightly towards x-motor-mount to tension it.
Use belt-clamp with 2x M5x10-bolt to clamp the right-side GT2-belt to the y-gantry
Tighten each M5x10-bolt to 0.5 N.M

Step 26 of 37

Tension Belt

Rotate the M3x16-bolt clockwise on belt-tensioner-arm installed on x-idler-mount to tension the GT2-belt
This will cause the belt-tensioner-arm to pull the idler-pulley away from x-idler-mount adding desired tension to the GT2-belt

Step 27 of 37

Trim excess belt

For the x-motor-mount side of the x-gantry-back print, trim loose GT2-belt until flush against belt-clamp
For the x-idler-mount side of the x-gantry-back print, trim loose GT2-belt until approx. 15mm of GT2-belt remains past belt-clamp

Step 28 of 37

Confirm progress

Check that finished x-linear-axis matches the image before proceeding

Step 29 of 37

Prepare NEMA-17-stepper-motor for z-axis

Set timing-pulley height on NEMA-17-stepper-motor shaft with jig
The 1st set-screw tightened must contact the flat region of the motor’s shaft

Note

Tighten both set screws to 0.4 N/M

Step 30 of 37

Prepare z-belt-subassembly

Prepare z-gantry-backplate-right
- Drill out the limit switch striker bolt hole on z-gantry-backplate-right with a 2.5mm drill bit
- Install 1x M3x16-flathead-bolt into z-gantry-backplate-right to a depth that roughly matches the image shown below
  - This screw depth will be precisely adjusted in later steps
Install both z-gantry-backplate-left and z-gantry-backplate-right onto gt2-belt-loop
- Place a gt2-belt-loop onto the z-belt-alignment-jig
- Place z-gantry-backplate-left and z-gantry-backplate-right onto the z-belt-alignment-jig to align them correctly on the gt2-belt-loop
- Twist z-gantry-backplate-left upwards to pull the completed z-belt-subassembly off of the z-belt-alignment-jig
- Use a dull knife or other tool to push the gt2-belt-loop all the way down into the cavity of each z-gantry-backplate-####
TO DO: Add info about LOCTITE 435 Usage

Step 31 of 37

Install M5-lock-nut into x-gantry-front

Use an arbor press to install an M5-lock-nut into backside of x-gantry-front

Step 32 of 37

Install 2x linear rail onto x-gantry-front

Install 2x linear-rail by aligning them against the bumps found on x-gantry-front
- Uses 3x M3x12-self-tapping-button-head per linear-rail
- Tighten each bolt in place with the electic torque driver

Step 33 of 37

Install z-axis-limit-switch

Secure with 2x M3x12-self-tapping-button-head
- Tighten each screw in place with the electic torque driver
Make sure each limit switch clicks and feels normal when actuated

Step 34 of 37

Install z-axis belt drive components

Secure idler-pulley onto x-gantry-front with 1x M5x25-bolt, tightened enough that the pulley can rotate freely without resistance
Check that the pulley can only rotate - it should not be able to move up and down if the bolt is tightened correctly
Begin by placing z-belt-subassembly onto x-gantry-front
- The z-gantry-backplate-right should fit over the right linear-rail-carriage, and the same goes for the left-side
- The gt2-belt-loop should wrap around the idler-pulley
Install the NEMA-17-stepper-motor by angling it into the z-belt-subassembly
- The limit switch connector will be at a 45º from the motor’s connector when everything is in the proper position.
Bolt NEMA-17-stepper-motor onto x-gantry-front with 4x M3x8-bolt
- Leave the bolts loose for now
Tension gt2-belt-loop by pulling the motor upwards before tightening the mounting bolts to 0.5 N/M
- The belts should feel much firmer now - to test manually move the z-axis back and forth while inspecting the belts for sag when changing directions
- You should be able to pluck the belt like a bass string
The x-gantry-front should now match the image shown below:

Step 35 of 37

Install 2x z-gantry

Loosely attach a z-gantry onto the left-side linear-rail-carriage with 4x M3x8-bolt per side
Align z-gantry parallel to linear-rail by lightly pressing it outward, while tightening the mounting bolts
- Tighten bolts to 0.5 N/M, moving in a star pattern
Repeat this process to attach the second z-gantry to the right-side linear-rail-carriage

Step 36 of 37

Install NEMA11-hollow-shaft-stepper

Bolt NEMA11-hollow-shaft-stepper onto left-side z-ganty
- Attach with 4x M2.5x8 bolts
- Torque each bolt to 0.3 N/M

Step 37 of 37

Install toolhead components

Slide nozzle-mask onto nozzle-holder as shown in the image below
Place rotary-pneumatic-adapter into rotary-pneumatic-adapter-socket
- Attach the custom socket to a torque driver if you have not already done so
- Set the torque driver to 0.5 N/M for the following steps
Install nozzle-holder and rotary-pneumatic-adapter onto NEMA11-hollow-shaft-stepper
- Begin by loosely threading nozzle-holder w/attached nozzle-mask onto the NEMA11-hollow-shaft-stepper (on the side closest to the idler-pulley)
- Install rotary-pneumatic-adapter onto NEMA11-hollow-shaft-stepper (on the side closest to the motor's cable connector)
- Place a 16mm wrench onto the flats found on nozzle-mask
- Tighten the toolhead components onto the NEMA11-hollow-shaft-stepper by torquing the rotary-pneumatic-adapter
Repeat above process to attach a rotary-pneumatic-toolhead-assembly to the left-side z-gantry