Oranj Reprap Prusa i3 3D Printer

Oranj Reprap Prusa i3 3D Printer by Chad Wick [Work in Progress last updated Dec20,2019]

This printer is almost complete, only build the small version until firmware is made for the larger sizes or you know how to edit firmwares yourself please contact me.

Unique Features:

-Print from 20cm up to 50cm cubed print volume depending which build you choose to make.

-Upgrade to a larger printer anytime, the majority of parts are still usable after an upgrade.

-Multi material up to 3 colors with two bowden and one direct drive extruder

-Fast(est?) 3D printer self replication print times

Tests done so far:

-Direct drive and Bowden Extruders has been tested to make Benchys and work to a good level of print quality.

-Very tall objects that max out Z height print successfully.

-I found a basic version of Marlin firmware with auto bed level enabled works with the smallest 22x22cm bed printer design.

whats left for me to do?:

-3D printed frame; test integrity of each printer size, make alterations if needed.

-type up parts list

-make build instructions as text/images. Also make video build instructions.

-Control boards and PSU enclosure need to be designed in CAD. May need a few designs made for different boards and PSU sizes.

-Firmware for printer sizes larger than 20cm bed and to enable multi color printing for boards that support 3 extruders.

Files in these folders correspond to the printer size you want to build:

22cm bed printer: “Oranj Printer Core Parts” + 22cm parts folder

30-40cm printer: “Oranj Printer Core Parts” + 30-50cm Shared Parts + 30-40cm parts folder

50cm printer: “Oranj Printer Core Parts” + 30-50cm Shared Parts + 50cm parts folder

Fun facts:

-This printer was designed in Maya because its all I know how to use.

-The name “Oranj 3D Printer” is mostly random. Searching on google will lead to this thingiverse design more easily because its misspelled with a J.

-Brief History; This printer started as a discontinued prusa i3 clone from aliexpress with aluminum 2020 extrusion frame and acrylic parts.

It was a poor design so I remade all parts into better printable designs.

tags: oranj 3D printer, reprap, prusa, filament, orange, open source, marlin

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More detailed notes:

PLA parts wight total for small printer:

900g to 1kg

@ 10% infill, 3 perims = 900g

@ 20% infill, 3 perims = 985g

PETG parts:

@ 20% infill, 3 perims = 250g

Flexible TPU Feet x4

@ 20% infill, 3 perims = 50g

X and Y axis takes up 180mm and Z axis takes up 140mm, anything above this in linear rod length = useable build volume

400mm rods: 220mm in X and Y and 260mm Z height

600mm rods: 420mm in X and Y and 460mm Z height

700mm rods: 520mm in X and Y and 560mm Z height

The differences between the smallest printer and larger sizes is the frame extensions, different legs design and more of them, no frame mounted spool holders so larger versions must use external holders.

Bed carriage is modular build and can hold 30 or 40cm beds in on design or only 50cm beds in another design. New firmwares [needed] to accommodate printer size changes.

Majority of the parts are the same such as the extruder and the core frame is the same only with extensions.

220mm bed carriage can be entirely printed on a prusa MK2 or better at is utmost print area of 216.5 in Y by 220mm. Other sizes are modular and must be assembled.

If using metal extrusion lengths:

220x220x260: (20cm x4) OR (40cm x2) for Y axis… (23cm x2) for X axis… (23cm x4) OR (46cm x2) for Z axis.

420x420x460 & 320x320x460: (30cm x4) OR (60cm x2) for Y axis… (43cm x2) for X axis… (33cm x4) OR (66cm x2) for Z axis.

520x520x560: (35cm x4) OR (70cm x2) for Y axis… (53cm x2) for X axis… (38cm x4) OR (76cm x2) for Z axis.

MAX: 30cm extrusion prints can be made on a 20x25cm bed like Prusa MK2/MK3 on a diagonal

MAX: metal heated bed is 30cm, for 40cm volume use 30x30cm heated pad on glass and 40cm heated pad for 50x50cm glass.

3D prints on corners will hold the glass plate to carriage. Aluminum sheet pieces taped under the glass bed will trigger probe for mesh bed leveling.

holes distances and true bed sizes

20cm bed: 220x220mm wide, 210mm space between center of holes

30cm bed: 327mm wide, 320.4mm space between center of holes

40cm bed: N/A (cant find, use glass and silicone heat pad)

50cm bed: N/A (cant find, use glass and silicone heat pad)