Extruder

Build Manual
RapMan V3.0.0

DocumentNo:D100237

Ver 1.2

Extruder Build Manual: RapMan V3.0.0

Contents

Section Title

Page

Contents
BuildManualInstruction

i
ii

Section Title

Page

Extruder
Section1
101
HeaterBarrel
102
ClampNutHolders
103
DriveShaft

Section2to5
201
DrivePlate
301
DriveHead
401
StepperMotor
501
SpacerBolts

DocumentNo:D100237

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Extruder Build Manual: RapMan V3.0.0

Using the Instructions & 3D PDFs

PleasereadandwatchtheseinstructionsbeforestartingtobuildyourRapManV3.0.0Extruderinordertogetthe
mostoutofyourcompletedRapManExtruder.
Theseinstructionsaredesignedtobeusedonacomputerastheyarefullyinteractive,printedcopieswillnotallow
interactionwiththe3Dmodelsorviewingtheanimations/videos.
Themanualisbrokendownintosectionsallthepartsinonesectioncanbebuiltsimultaneouslyi.e.allthe1xxitems
canbebuiltatthesametime.TheSection2xxbuildswillrequirepartsfromthesection1xxbuildsandsection3xx
fromsection2xxandsoon.
SettingupthePDFenvironment:
ThisdocumentisbestviewedinAdobeAcrobatReader9.
Set the document to view Two Up go to View Page Display Two Up this will allow you to see the
instructionpageontheleftandtheanimationontheright.
3DMenuBar

Rotate

Lights

BackgroundColour

ModelTree

Home

PartsList
Animation

SelectedPart
ToolsRequired
DangerHazards

SpecialCareNotes

UsingtheinteractivePDF:

Build
Instructions

Interactive3DPDFsallowtheusertoseealltheinformationnormallyonlyavailabletotheoriginaldesigner
the models can be rotate and zoomed, individual parts can be turned on and off to allow the user to see
hiddenpartsorabetterviewofdifficulttounderstanditems,thisistrueforboththestatic3Dmodeland
the3Danimation.
Allthe3Dmodelscanbeinteractedwith,toenableinteractionclickonthemodelandthe3Dmenubarwill
openallowingthemodeltoberotated,panned,zoomed,sectionedetc.
The background colour, model display and lighting can also be changed the view can always be reset by
pressingthehomebutton.
Iftheanimationdoesntstartasthepageismadevisible,clickonthemodel,selectingthedropdownonthe
play/pausebuttonwilldisplayatimelinecontrolallowingyoutopositionthebuildatanypointrequiredthe
modelcanthenberotatedetctogetabetterview
Selectingthemodeltreedisplaywillallowyoutoclickonanyiteminthemodelortreeandthepartwillbe
highlightedinboththemodelandthemodeltree,thisallowsveyeasyidentificationofallparts.

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Extruder Build Manual: RapMan V3.0.0

Intentionally Blank

DocumentNo:D100237

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Extruder Build Manual: RapMan V3.0.0

Name: Heater Barrel

Build #: 1-01

Level: Difficult
Part#

Heater
Barrel
Heater
Barrel

Previous Builds Required: None

Qty
1
1

Mounting
Plate
NiChrome 180mm

Wire
Bootlace
4

Ferrule
24SWG
200mm

Wire
FireCement

Tools:

Pliers/CrimpTool
MultiMeter
SmallFlatScrewdriver(tosmoothfire
cement)
Bulldogclips

:None

:None

BuildingtheExtruderHeaterBarrel.

Aspervideoabove

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Extruder Build Manual: RapMan V3.0.0

Name: Clamp Nut Holders

Build #: 1-02

Level: Difficult
Part#

10107

M3Nuts
M3x35CP

Previous Builds Required: None

Qty
2
2
2

Tools:

SolderingIron
Pliers
2.5mmAllenKey

:HotSolderingIronand

heatedparts.

Installingtheretainednuts.

Aspervideoabove

:Ensurepartsarealigned

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Extruder Build Manual: RapMan V3.0.0

Name: Drive Shaft

Build #: 1-03

Level: Easy
Part#

10050
10051
10052
20010
608ZZ

Bearing
M8Nut

M8Nut
M8Spring

Washer
M8Washer

Previous Builds Required: None

Qty
1
1
1
1
2
1
1
1
1

Tools:

13mmSpannerx2

:None

:None

BuildingtheDriveShaft.

Looselyfitthe608bearing,springwasher,drivengear(10052),washer&nutto
thedriveshaft(20010)ontheendwiththelongerbearinglandsection
Looselyfitthe2nd608bearing,washer&nuttotheotherend
Tightenbothnutsatthesametimeuntilthespringwasherisfullycompressed
Slide on the motor mounting plate (10050) being careful to ensure the correct
orientation
Slide on the bearing mount (10051) again being careful to ensure correct
orientation

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Extruder Build Manual: RapMan V3.0.0

Build #: 1-03 Animation

Level: Easy Previous

Name: Screw Drive

Builds Required: None

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Extruder Build Manual: RapMan V3.0.0

Name: PTFE Modification

Build #: 1-04

Level: Easy
Part#

PTFE

Insulator
Cutsection

ofheater

Previous Builds Required: None

Qty
1
1

barrel/10mm
olive

Tools:

Drill
4mmDrillBit
4.5mmDrillBit
5mmDrillBit
10mmDrillBit

Pliers

:Electricdrillrotatingcutter

hazard

: Take
care using the drill to
drillconcentrictotheinsulator

PTFEMods.

This modification is not strictly required but will improve the life of the PTFE
insulatorandmakeitmorereliableandmoreabletoresistablockageduetothe
nozzlerunningtoclosetotheprintingbed
Modificationaspervideo&drawingabove
Ifthecutsectionofheaterbarrelhasbeendamageda10mmplumbingolivecan
beused
ThepurposeistoprovidemechanicalsupporttothehotsectionofPTFEwitha
coolermetalring

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Extruder Build Manual: RapMan V3.0.0

Name: Pressure Bearings

Build #: 1-05

Level: Easy
Part#

10085
10086
6232Z

Bearing
M3x30CP

M3Nut
M3Washer

Previous Builds Required: None

Qty
4
4
2
2
2
8

Tools:

5.5mmSpanner
2.5mmAllenKey

:None

:None

PressureBearings.

Assembleasperthedrawingabove
Put the top surface (with side to the bearings) onto a flat surface when
tighteningthe2M3bolts,thiswillhelpkeepthepartsaligned

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Extruder Build Manual: RapMan V3.0.0

Name: Conduit

Build #: 1-06

Level: Easy
Part#

PPConduit

Previous Builds Required: None

Qty
1.4m

Tools:

Knife
InsulationTapeBlack
CuttingBoard

:Knife

:None

PreparingtheExtruderConduit.

Cut1x50mmand4x25mmofconduit
Tapethecutsectionstothemain1.25mlengthofconduitasperthedrawing&
photoabove.

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Extruder Build Manual: RapMan V3.0.0

Name: Stepper Wiring

Build #: 1-07

Level: Moderate
Part#
StepperMotor

RedWire650mm
BlackWire650mm

BlueWire650mm
GreenWire

650mm
Heatshrink1.6mm

x20mm

Previous Builds Required: 1-01, 1-04

Qty
1
1
1
1
1
4

Tools:

SolderingIron
WireCutters
WireStrippers
HelpingHandclamp
Hotairforheatshrink

:HOTSOLDERINGIRON

:
Always tin the wires to
a good mechanical &
ensure
electricaljoint

WiringtheHeaterBarrel.

Jointhewiresredtored,greentogreen,blacktoblack&bluetoblue
Heatshrinkoverthejoin
TwisttheBlack&GreenwirestogetherandtheRed&Bluewires,thisistwisting
thephasewirestogetherandhelpsreduceelectricalnoise.

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Extruder Build Manual: RapMan V3.0.0

Name: Z Depth Stop

Build #: 1-08

Level: Moderate
Part#
10056
10077
10078

M5x70Hex
M5Nyloc

M5Nut
M5Washer

M3x20CP
M3Nut

M3Washer

Qty
1
1
1
1
1
1
1
1
1
2

Previous Builds Required: None

Tools:

8mmSpannerx2
5.5mmSpanner
2.5mmAllenKey

:None

:
Ensure correct orientation,

be careful
fitting the M5 Bolt not
tobreaktheplastic

ZDepthStop.

InserttheM5nylocnutintothenylocretainer(10077)ensuringthenylonisat
thetop
Boltthenylocretainer(10077)andnylocbacking(10078)totheextruder
mountingplate(10056)aligningthe5mmholes
FittheM5x70Boltandthewasher&M5locknut

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Extruder Build Manual: RapMan V3.0.0

Name: Fan Connector

Build #: 1-09

Level: Moderate
Part#
FanPowerPlug

RedWire1.9m
BlackWire1.9m

Previous Builds Required: None

Qty
1
1
1

Tools:

SolderingIron
WireCutters
WireStrippers
HelpingHandclamp

:HOTSOLDERINGIRON

:
Always tin the wires to
a good mechanical &
ensure
electricaljoint

WiringtheFanPowerPlug.

SoldertheRedwiretothecentretab
Soldertheblackwiretotheoutertab
Clampthewiresinthecableclamp
TwisttheRed&Blackwirestogetherfortheirfulllength

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Extruder Build Manual: RapMan V3.0.0

Name: Drive Plate

Build #: 2-01

Level: Moderate
Part#

10054
10055
10057

M5x25CP
M5x20CP

M5Nut
M5Washer

M3x35CP
M3x25CP

M3Nut

M3Washer

Qty

Previous Builds Required: 1-02

1
1
1
6
1
7
19
2
2
2
4

Tools:

8mmSpanner
5.5mmSpanner
4mmAllenKey
2.5mmAllenKey

:None

:None

DocumentNo:D100237

BuildingtheExtruderDrivePlate.

Placethe8mmthickmainplate10054ontoaflatsurface
Placethe11off5mmwashersontothemainplate
Layinplacethe3mmthickfilamentspacer10055beingcarefulnottodislodge
thewashers
Laythe5mmthicktopplate10057intoplaceagaintakingcarenottodislodge
thewashers
Carefullyinsertalltheboltsensuringtheygothroughthetrappedwasher
Lifttheassemblykeepingitflatsotheboltsdonotfallout
LooselyfitallthenutsexpecttheM3ones
Fitthe2offclampnutholderscompletewithM3nuts
LooselyfittheM3x35boltstoretainthetrappedwashers
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Extruder Build Manual: RapMan V3.0.0

Name: Wiring Heater Barrel

Build #: 2-02

Level: Difficult

Previous Builds Required: 1-01, 1-04

Part#
Qty

10064
1

Yellow
120mm
Sleeving

GreyWire
3.8m
PurpleWire
3.8m

Bootlace
4
Ferrule

M3x40
3
Stainless

SteelSpacer
M3x12CP
3

M3Nut
3

M3Washer
9

Tools:

5.5mmSpannerx2
2.5mmAllenKey
Pliers
WireCutters
WireStrippers

:None

:None

WiringtheHeaterBarrel.

Aspervideoabove

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Extruder Build Manual: RapMan V3.0.0

Build #: 2-01 Animation

Level: Moderate

Name: Drive Plate

Previous Builds Required: 1-02

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Extruder Build Manual: RapMan V3.0.0

Name: Drive Head

Build #: 3-01

Level: Easy
Part#

Filament

Previous Builds Required: 1-03 & 2-01

Qty

Tools:

8mmSpanner
5.5mmSpanner
SmallLongNosePliers
4mmAllenKey

:None

:
Do
Not over tighten the M5

bolts

BuildingtheExtruderDriveHead.

Removethelooselyfittednutsasshownintheanimation
Slidethedriveshaftassemblyintothedriveplate
This should be a simple sliding fit and if it needs forcing adjust the drive plate
untilitisasimpleslidingfit
Fitthenutsintotheirhousingsoneatatime,tighteningtheM5boltsasyougo
becarefulnottoovertightentheM5bolt
Smalllongnoseplierscanhelpwheninsertingthenuts
When assembled check with the filament that it slides easily through the
filamentslotinthedriveplate

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Extruder Build Manual: RapMan V3.0.0

Build #: 3-01 Animation

Level: Easy Previous

Name: Drive Head

Builds Required: 1-03 & 2-01

DocumentNo:D100237

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Extruder Build Manual: RapMan V3.0.0

Name: Stepper Motor

Build #: 4-01

Level: Easy
Part#

10053
FL42
Stepper
Motor
M3x10CP

M3x6Grub
Screw

M3Nut
M3Washer

Previous Builds Required: 3-01

Qty
1
1

4
1
1
4

Tools:

2.5mmAllenKey
1.5mmAllenKey
File
2mmDrillBit
Grease

:None

:None

FittingtheExtruderStepperMotor.

DocumentNo:D100237

File a flat on the stepper motor shaftso the Grub screw has agood grip (note
theM3Nutwillnotfitunlesstheshaftisfiled)
Drillthedrivegear(10053)aspertheabovedrawingwith2mmdrillbit
Fit the stepper motor to the motor mounting plate such that the wires are on
therightwhenlookingatthesteppermotor,uppermostcorner
Boltdownwiththe4M3x10CPboltsandM3washers
Fitthedrivegear(10053)tothemotorshaftslidedownuntilitisflushwiththe
drivengear
Rotatethedrivegearuntilthenutrecessalignswiththeflatonthemotorshaft
FittheM3nut&grubscrewandtighten
Ensureyoucaneasilyrotatethesteppergearapplyalittlegrease tothegears
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Extruder Build Manual: RapMan V3.0.0

Build #: 4-01 Animation

Level: Easy

Name: Stepper Motor

Previous Builds Required: 3-01

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Extruder Build Manual: RapMan V3.0.0

Name: Spacer Bolts

Build #: 5-01

Level: Easy
Part#

M8x120
Bolt
M8Nut

M8washer
8RodEnd

Previous Builds Required: 4-01

Qty
2
6
8
2

Tools:

13mmSpannerx2

:None

:None

FittingtheSpacerBolts.

PuttheM8x120boltcompletewithwasherthroughthemotormountingplate
Beforegoingthroughthetopbearingmountingplatefit1M8washer,2M8Nuts
andanotherM8washer
Clampthebolttothemotormountingplate
Setthetopnutssuchthatthemotormountingplateandthebearingplateare
parallel
Tightenthetwotopnutsensuringtheplatesremainparallel
Pushfitthe2rodendcovers

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Extruder Build Manual: RapMan V3.0.0

Name: Conduit Mount

Build #: 6-01

Level: Easy
Part#

10073

M5x20CP
M5Nut

M5Washer

Previous Builds Required: 5-01

Qty
1
2
2
2

Tools:

4mmAllenKey

:None

:None

ConduitMount.

PuttheM5Boltsthroughthewashersandconduitmount(10073)
SlidetheNutsintotheirhousings
Lowertheconduitmountintoplaceandtighten

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Extruder Build Manual: RapMan V3.0.0

Name: Mounting Heater Barrel

Build #: 7-01

Level: Easy
Part#

M5x25Hex

M5Nut
M5Washer

Previous Builds Required: 1-08, 2-02 & 6-01

Qty
2
2
2

Tools:

8mmSpanner

:None

:None

MountingtheHeaterBarrel.

FittheM5x25Boltsintotheirhousings
SlideovertheExtrudermountingplate(stage108)
Feed the heater wires through the extruder mounting plate (as shown in the
nextsection)andslidetheheaterbarrelplateontotheM5x25Bolts
FittheM5washers&M5nutsandtighten

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Extruder Build Manual: RapMan V3.0.0

Name: Extruder Loom

Build #: 8-01

Level: Easy
Part#

Previous Builds Required: 7-01

Qty

Tools:

None

:None

:None

ExtruderLoom.

Feedthewiresthroughtheextruderasperthevideo

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Extruder Build Manual: RapMan V3.0.0

Name: Extruder Connector Plug

Build #: 9-01

Level: Easy
Part#

12Way

Connector
Connector

Terminals
4K7Resistor

2.4mmHeat
shrink7mm

Previous Builds Required: 8-01

Qty
1
10
1
1

Tools:

SolderingIron
WireCutters
WireStrippers
HelpingHand
clamp

:HOTSOLDERINGIRON

:
Always tin the wires to
a good mechanical &
ensure
electricaljoint

ExtruderConnector.

Connectallwiresasperthevideo&drawing
Alsoseeschematicintheappendix
Never disconnect the extruder while the board is powered it will destroy the
stepperdriverchip

Never disconnect the extruder

whiletheboardispowereditwill
destroythestepperdriverchip

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Extruder Build Manual: RapMan V3.0.0

Appendix

1. WiringSchematicExtruder
2. PTFEModifications
3. ConduitCutting&Assembly

DocumentNo:D100237

Ver 1.2

Ver 1.2

10
7
5

3,5

4,5

Designed by

Office

Checked by

Approved by

Date

Date

23/04/2009

20014-1 PTFE Insulator

2

Edition

Ver 11.2

Sheet

1/1

1250

10

A
B

100

25

100

25

25

100

Designed by

25

Checked by

Approved by

Date

Date

31/03/2009

Office

50

100

Conduit
2

Edition

Ver 11.2

Sheet

1/1