RepRap Ormerod First Upgrade and Lessons Learned

Upgrading the Z runner mount on an early kit, lessons learned and thoughts on RepRap.

As I mentioned in my previous post which covered commissioning and a first print, I received one of the very earliest Ormerod kits — number 005, no less! — and since then there have been a number of improvements made to the design, with one of these being to the Z runner mount.

One of the great things about RepRap's self-replicating approach is that not only can you print out parts for a new printer, but you can also print improved parts for use in upgrades. Above can be seen a new adjustable Z runner mount in white PLA, alongside the original non-adjustable mount.

The print quality of the new part isn't quite up to that of the one supplied with the kit, but that's actually the point here; the new mount removes play in the X arm by allowing the runner bearing to be adjusted closer to the Z axis extrusion, which will result in smoother prints from now on.

At this point I should make clear that new kits include the improved Z runner mount.

The countersunk screw pointing to the bottom-right corner is used to adjust the mount to bring the Z runner bearing closer to the axis.

Lessons learned

Although I was previously involved in putting together a predecessor of the Ormerod, I would consider myself anything but a 3D printing expert; while perfectly comfortable with the electronics and firmware etc. side of things, I am much less so when it came to the mechanics of machine and printing.

Here are some of the most important lessons I've learned so far and tips for those embarking on constructing their own RepRap.

Construction

• Ensure that you have all the required tools to hand before starting

• Make sure you have somewhere comfortable to work and plenty of light, as it can get quite fiddly

• It's worthwhile taking the time to prepare the parts required for each stage of construction before starting

• Use a file to clean up any printed parts (and never force them!)

• Check and re-check at each stage (to avoid having to later dismantle and reassemble)

• If you're not sure about something, consult the forums as it may have previously been discussed — don't just stare at the documentation and get frustrated!

Commissioning and printing

• Ensure that you have the latest version of the firmware (on the controller board and SD card)

• If you get stuck during commissioning, as with construction, consult the forums!

• Clean the print bed with alcohol or similar, even if it doesn't look like it needs it, and in particular where you experience any issues with prints not sticking

• Setting the Z probe and bed compensation (or levelling the bed) is vital and if these steps are not completed you are extremely unlikely to succeed in getting successful prints

Needless to say that I'm sure I will learn much more as I spend more time with the machine.

Kits vs. ready to use printers

The most obvious benefit of assembling a 3D printer from a kit is cost. However, this is only part of the story with a RepRap, and you also end up with a machine that has a dedicated and passionate community developing modifications and upgrades, and which is only too happy to provide help to those who are new to 3D printing and/or the RepRap family of machines.

I have to say that it felt pretty amazing to be able to clone the Ormerod GitHub repository, identify an upgraded part and then slice and print this, before using it to upgrade the machine that printed it! And I am sure that this was only the first of numerous upgrades that I will apply to the Ormerod over the course of its lifetime. Indeed, it's even possible that one day I'll be using it to print out a set of parts for a new RepRap design, to which the Ormerod will be donor for steppers motors etc...

— Andrew Back