This version used for kits 7-

Nut traps moved further from the edge of most parts. Fixed ribbon clamp slots too deep. Modified for JHeadMK5. Changed bed thermsitor type. Extruder block is now thinner so it can protrude below the carriage. The idler bolts no go the other way round so the nuts are captive instead of the heads. 60 mm carriage fan. Spool holders now have tabs for nut traps instead of P clip. Belt lengths corrected and rounded to tooth pitch. Metal pulleys modelled. exploded variable now 0/1 instead of boolean. Dibond version now has mouse holes for wires and the Y wires run underneath the base. Added jigs for inserting Jhead and drilling tubes. Hobbed bolt not shows hob position on the BOM. Everything in the kit is now in the model and so appears on the BOM. Added ribbon cable, wire, heat shrink sleeving, foam spunge, PLA sample. Completed the kit build manual. Sub assemblies restructured to reflect the build order. View files added to make the assembly diagrams. Fixed sheets.py not working first time run.
bjmckenz · Nov 17, 2012 · 2f70825 · 2f70825
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commit 2f70825
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Showing 530 changed files with 563,371 additions and 473,288 deletions.
diff --git a/dibond/Mendel90_Dibond.pdf b/dibond/Mendel90_Dibond.pdf
diff --git a/dibond/bom/D_connector_assembly.txt b/dibond/bom/D_connector_assembly.txt
diff --git a/dibond/bom/bed_assembly.txt b/dibond/bom/bed_assembly.txt
diff --git a/dibond/bom/bom.txt b/dibond/bom/bom.txt
diff --git a/dibond/bom/electronics_assembly.txt b/dibond/bom/electronics_assembly.txt
@@ -1,27 +1,14 @@
 electronics_assembly:
 Vitamins:
-  1 THS15 Aluminium clad resistor 10R
-  1 THS15 Aluminium clad resistor 4R7
-  1 PSU e.g. ALPINE500
   4 M3 cap screw x 16mm
-  4 M4 cap screw x 16mm
-  1 IEC mains lead
   1 Electronics e.g. Melzi
-  4 Nyloc nut M2.5
   4 Nyloc nut M3
-  4 Nyloc nut M4
-  4 M2.5 pan screw x 12mm
-  2 6-32 pan screw x 9.5mm
   1 Micro SD card
   1 Micro SD to USB adapter
+  2 Heatshrink sleeving ID 2.4mm x 15mm
   1 USB A to Mini B lead
-  4 Washer M2.5 x 5.9mm x 0.5mm
   8 Washer M3 x 7mm x 0.5mm
-  6 Washer M4 x 9mm x 0.8mm
-  2 Star washer M4 x 0.8mm
 
 Printed:
-  1 atx_long_bracket.stl
-  1 atx_short_bracket.stl
   4 pcb_spacer.stl
 
diff --git a/mendel/bom/wades_assembly.txt → dibond/bom/extruder_assembly.txt b/mendel/bom/wades_assembly.txt → dibond/bom/extruder_assembly.txt
@@ -1,33 +1,25 @@
-wades_assembly:
+extruder_assembly:
 Vitamins:
   3 Ball bearing 608 8mm x 22mm x 7mm
-  1 M3 grub screw x 6mm
-  1 JHead MK4 hot end
   3 M3 hex screw x 10mm
   2 M4 hex screw x 20mm
   2 M4 hex screw x 50mm
-  1 M8 hex screw x 60mm
-  1 NEMA17 x 47.5mm stepper motor
-  1 Nut M3
+  1 M8 hex screw x 60mm, hobbed at 25
   2 Nut M4
   2 Nut M8
   1 Smooth rod 8mm x 22mm
   2 Spring 7mm OD, 1mm gauge x 10mm long
-  2 PTFE sleeving OD 1.2mm ID 0.71mm x 57mm
-  2 PTFE sleeving OD 2.6mm ID 2mm x 45mm
   3 Washer M3 x 7mm x 0.5mm
-  1 Washer M8 x 17mm x 1.6mm
   3 Star washer M3 x 0.5mm
   1 Star washer M8 x 1.6mm
-  1 Ziptie 100mm min length
 
 Printed:
-  1 feed_tube_connector.stl
+  1 jhead_insertion_jig.stl
   1 wades_big_gear.stl
   1 wades_block.stl
   1 wades_gear_spacer.stl
   1 wades_idler_block.stl
-  1 wades_small_gear.stl
 
 Sub-assemblies:
-  1 D_connector_assembly
+  1 extruder_motor_assembly
+  1 hot_end_assembly
diff --git a/dibond/bom/extruder_connection_pcb_assembly.txt b/dibond/bom/extruder_connection_pcb_assembly.txt
@@ -0,0 +1,7 @@
+extruder_connection_pcb_assembly:
+Vitamins:
+  1 Extruder connection PCB
+  4 3 way terminal block
+
+Printed:
+
diff --git a/dibond/bom/extruder_motor_assembly.txt b/dibond/bom/extruder_motor_assembly.txt
@@ -0,0 +1,18 @@
+extruder_motor_assembly:
+Vitamins:
+  2 M3 cap screw x 45mm
+  1 15 way D PCB mount plug
+  1 M3 grub screw x 6mm
+  1 NEMA17 x 47.5mm stepper motor
+  3 Nut M3
+  2 No2 pan wood screw x 13mm
+  2 Washer M2.5 x 5.9mm x 0.5mm
+  2 Washer M3 x 7mm x 0.5mm
+
+Printed:
+  1 d_motor_bracket.stl
+  1 d_motor_bracket_lid.stl
+  1 wades_small_gear.stl
+
+Sub-assemblies:
+  1 extruder_connection_pcb_assembly
diff --git a/dibond/bom/frame_assembly.txt b/dibond/bom/frame_assembly.txt
@@ -5,8 +5,6 @@ Vitamins:
   1 Dibond sheet 465mm x 384mm x 3mm
   1 Dibond sheet 465mm x 419mm x 3mm
  36 Nyloc nut M4
-  1 Polypropylene strip 356mm x 25mm x 0.5mm
-  1 Polypropylene strip 270mm x 33mm x 0.5mm
   2 AL square tube 12.7 x 12.7 x 1.63 x 400mm
  38 Washer M4 x 9mm x 0.8mm
  10 Ziptie 100mm min length
@@ -16,6 +14,5 @@ Printed:
   1 ribbon_clamp_20_44N.stl
   1 ribbon_clamp_26_44N.stl
   4 tube_cap.stl
+  1 tube_jig.stl
 
-Sub-assemblies:
-  1 spool_holder_assembly
diff --git a/dibond/bom/hot_end_assembly.txt b/dibond/bom/hot_end_assembly.txt
@@ -0,0 +1,13 @@
+hot_end_assembly:
+Vitamins:
+  1 JHead MK5 hot end
+  2 PTFE sleeving OD 1.2mm ID 0.71mm x 62mm
+  2 Heatshrink sleeving ID 1.6mm x 15mm
+  2 PTFE sleeving OD 2.6mm ID 2mm x 45mm
+  2 Heatshrink sleeving ID 2.4mm x 15mm
+  1 Heatshrink sleeving ID 6.4mm x 60mm
+  2 Red wire 16/0.2 length 170mm
+  1 Ziptie 100mm min length
+
+Printed:
+
diff --git a/dibond/bom/machine_assembly.txt b/dibond/bom/machine_assembly.txt
@@ -7,7 +7,8 @@ Sub-assemblies:
   1 bed_fan_assembly
   1 electronics_assembly
   1 frame_assembly
+  1 psu_assembly
+  1 spool_holder_assembly
   1 x_axis_assembly
   1 y_axis_assembly
-  1 y_carriage_assembly
   1 z_axis_assembly
diff --git a/dibond/bom/print_bed_assembly.txt b/dibond/bom/print_bed_assembly.txt
@@ -0,0 +1,23 @@
+print_bed_assembly:
+Vitamins:
+  5 Aluminium foil tape 50mm x 226mm x 0.05mm
+  4 19mm bulldog clip
+  1 PCB bed 214mm x 214mm
+  1 Corrugated cardboard 192mm x 216mm x 6mm
+  4 M3 cap screw x 10mm
+  1 Glass sheet 214mm x 202mm x 2mm
+  4 Hex male / female pillar M3 x 20mm
+  1 Polypropylene strip 271mm x 33mm x 0.5mm
+  1 Ribbon cable 26 way 381mm
+  2 Heatshrink sleeving ID 1.6mm x 15mm
+  2 Heatshrink sleeving ID 2.4mm x 15mm
+  2 Heatshrink sleeving ID 6.4mm x 30mm
+  1 Epcos B57861S104F40 100K 1% thermistor
+  4 Washer M3 x 7mm x 0.5mm
+  1 Black wire 32/0.2 length 635mm
+  1 Red wire 32/0.2 length 620mm
+
+Printed:
+
+Sub-assemblies:
+  1 y_carriage_assembly
diff --git a/dibond/bom/psu_assembly.txt b/dibond/bom/psu_assembly.txt
@@ -0,0 +1,24 @@
+psu_assembly:
+Vitamins:
+  1 THS15 Aluminium clad resistor 10R
+  1 THS15 Aluminium clad resistor 4R7
+  1 PSU e.g. ALPINE500
+  4 M4 cap screw x 16mm
+  1 IEC mains lead
+  4 Nyloc nut M2.5
+  4 Nyloc nut M4
+  4 M2.5 pan screw x 12mm
+  2 6-32 pan screw x 9.5mm
+  1 Heatshrink sleeving ID 10mm x 15mm
+  3 Heatshrink sleeving ID 2.4mm x 15mm
+  5 Heatshrink sleeving ID 3.2mm x 15mm
+  2 Heatshrink sleeving ID 6.4mm x 15mm
+  4 Washer M2.5 x 5.9mm x 0.5mm
+  6 Washer M4 x 9mm x 0.8mm
+  2 Star washer M4 x 0.8mm
+  2 Ziptie 100mm min length
+
+Printed:
+  1 atx_long_bracket.stl
+  1 atx_short_bracket.stl
+
diff --git a/dibond/bom/spool_holder_assembly.txt b/dibond/bom/spool_holder_assembly.txt
@@ -3,16 +3,18 @@ Vitamins:
   4 Ball bearing 608 8mm x 22mm x 7mm
   2 M4 cap screw x 16mm
   4 M8 cap screw x 30mm
+  1 Foam sponge 20mm x 20mm x 20mm
   2 Nyloc nut M4
   4 Nyloc nut M8
+  1 PLA sample 0.3mm ~20m
   1 PTFE tubing OD 4.6mm ID 3.84mm x 750mm
   2 Washer M4 x 9mm x 0.8mm
   8 Washer M8 x 17mm x 1.6mm
   4 Washer M8 x 30mm x 1.5mm
 
 Printed:
   1 dust_filter.stl
+  1 feed_tube_connector.stl
   2 spool_bracket_female.stl
   2 spool_bracket_male.stl
-  2 spool_holder_p_clip.stl
 
diff --git a/dibond/bom/x_axis_assembly.txt b/dibond/bom/x_axis_assembly.txt
@@ -1,10 +1,12 @@
 x_axis_assembly:
 Vitamins:
-  1 Belt T5 x 6mm x 864mm (PU & Kevlar)
-  1 Polypropylene strip 401mm x 18mm x 0.5mm
+  1 Belt T5 x 6mm x 865mm (PU & Kevlar)
   2 Smooth rod 8mm x 381mm
+  2 Wingnut M4
 
 Printed:
 
 Sub-assemblies:
+  1 extruder_assembly
   1 x_carriage_assembly
+  1 x_carriage_fan_assembly
diff --git a/dibond/bom/x_carriage_assembly.txt b/dibond/bom/x_carriage_assembly.txt
@@ -1,23 +1,17 @@
 x_carriage_assembly:
 Vitamins:
-  1 M3 cap screw x 10mm
+  2 M3 cap screw x 10mm
   1 M3 cap screw x 20mm
   2 M3 cap screw x 25mm
-  1 Fan 30mm x 10mm
   3 LM8UU linear bearing
   1 Nut M3
-  3 Nyloc nut M3
-  4 No4 pan wood screw x 16mm
-  3 Washer M3 x 7mm x 0.5mm
-  2 Wingnut M4
+  4 Nyloc nut M3
+  4 Washer M3 x 7mm x 0.5mm
   3 Ziptie 100mm min length
 
 Printed:
   1 x_belt_clamp.stl
   1 x_belt_grip.stl
   1 x_belt_tensioner.stl
   1 x_carriage.stl
-  1 x_carriage_fan_duct.stl
 
-Sub-assemblies:
-  1 wades_assembly
diff --git a/dibond/bom/x_carriage_fan_assembly.txt b/dibond/bom/x_carriage_fan_assembly.txt
@@ -0,0 +1,11 @@
+x_carriage_fan_assembly:
+Vitamins:
+  4 M4 cap screw x 30mm
+  1 Fan 60mm x 15mm
+  4 Nyloc nut M4
+  4 Washer M4 x 9mm x 0.8mm
+
+Printed:
+  1 x_carriage_fan_bracket.stl
+  1 x_carriage_fan_duct.stl
+
diff --git a/dibond/bom/x_idler_assembly.txt b/dibond/bom/x_idler_assembly.txt
@@ -4,7 +4,6 @@ Vitamins:
   1 M4 cap screw x 45mm
   2 M3 hex screw x 16mm
   2 LM8UU linear bearing
-  1 Brass nut M6
   2 Nyloc nut M3
   1 Nyloc nut M4
   2 Washer M3 x 7mm x 0.5mm

diff --git a/dibond/bom/x_motor_assembly.txt b/dibond/bom/x_motor_assembly.txt
@@ -1,23 +1,31 @@
 x_motor_assembly:
 Vitamins:
-  2 M3 cap screw x 16mm
-  1 M3 grub screw x 6mm
+  4 M3 cap screw x 16mm
+  2 M3 cap screw x 20mm
+  1 15 way D IDC socket
+  1 M3 grub screw x 3mm
   4 M3 hex screw x 16mm
   2 LM8UU linear bearing
   1 NEMA17 x 47.5mm stepper motor
-  1 Brass nut M6
-  1 Nut M3
-  6 Nyloc nut M3
+  8 Nyloc nut M3
+  2 Nitrile O-ring 2.5mm x 1.6mm
+  1 Polypropylene strip 401mm x 18mm x 0.5mm
+  1 Polypropylene strip 357mm x 25mm x 0.5mm
   3 M3 pan screw x 8mm
-  2 No2 pan wood screw x 13mm
+  4 No2 pan wood screw x 13mm
+  1 T5 pulley 10 teeth
+  1 Ribbon cable 20 way 1120mm
   1 Microswitch
-  2 Washer M2.5 x 5.9mm x 0.5mm
-  9 Washer M3 x 7mm x 0.5mm
+  4 Heatshrink sleeving ID 2.4mm x 15mm
+  4 Washer M2.5 x 5.9mm x 0.5mm
+ 13 Washer M3 x 7mm x 0.5mm
   3 Star washer M3 x 0.5mm
 
 Printed:
-  1 pulley.stl
+  1 d_shell.stl
+  1 d_shell_lid.stl
   1 ribbon_clamp_14_33.stl
+  1 ribbon_clamp_14_33NB.stl
   1 ribbon_clamp_20_33.stl
   1 x_motor_bracket.stl
 
diff --git a/dibond/bom/y_axis_assembly.txt b/dibond/bom/y_axis_assembly.txt
@@ -1,6 +1,6 @@
 y_axis_assembly:
 Vitamins:
-  1 Belt T5 x 6mm x 673mm (PU & Kevlar)
+  1 Belt T5 x 6mm x 670mm (PU & Kevlar)
   4 M3 cap screw x 16mm
   8 M4 cap screw x 16mm
   4 Nyloc nut M3
@@ -18,5 +18,6 @@ Printed:
   1 y_bar_clamp_switch.stl
 
 Sub-assemblies:
+  1 print_bed_assembly
   1 y_idler_assembly
   1 y_motor_assembly
diff --git a/dibond/bom/y_carriage_assembly.txt b/dibond/bom/y_carriage_assembly.txt
@@ -1,7 +1,5 @@
 y_carriage_assembly:
 Vitamins:
-  5 Aluminium foil tape 50mm x 226mm x 0.05mm
-  1 Corrugated cardboard 192mm x 216mm x 6mm
  14 M3 cap screw x 16mm
   2 M3 cap screw x 20mm
   1 Dibond sheet 216mm x 216mm x 3mm
@@ -20,5 +18,3 @@ Printed:
   1 y_belt_clip.stl
   1 y_belt_clip_toothed.stl
 
-Sub-assemblies:
-  1 bed_assembly
diff --git a/dibond/bom/y_motor_assembly.txt b/dibond/bom/y_motor_assembly.txt
@@ -1,16 +1,15 @@
 y_motor_assembly:
 Vitamins:
   4 M4 cap screw x 16mm
-  1 M3 grub screw x 6mm
+  1 M3 grub screw x 3mm
   1 NEMA17 x 47.5mm stepper motor
-  1 Nut M3
   4 Nyloc nut M4
   4 M3 pan screw x 8mm
+  1 T5 pulley 10 teeth
   4 Washer M3 x 7mm x 0.5mm
   4 Washer M4 x 9mm x 0.8mm
   4 Star washer M3 x 0.5mm
 
 Printed:
-  1 pulley.stl
   1 y_motor_bracket.stl