Modular Prusa X-carriage & e3D Chimera mount (layers fans, bed levelling, cable chain) by RGN01

Last crawled date: 3 years ago

24/12/2015: I have now developed a new, simpler version of the fan mount and duct. Mine is printed and ready to mount and I will add updated files here once I have fitted and tested the parts.
27/10/2015: Uploaded a new duct (v3.00) I printed this in ABS and use 3mm magnets in the holes to mount it. I drilled the actual Chimera mount 2mm duct mount holes out to 3mm to add 3mm diameter x 4mm long magnets to that to retain the duct. A new Chimera mount will follow (I've stopped using the Z-probe so will simplify the mount).
26/07/2015: Added the components for the servo mount, servo arm and lifting arm to enable auto bed level compensation. It uses a SG-90 servo.
19/07/2015 update: Uploaded the more complex Chimera mount and the layer fan duct.
14/07/2015 update: electronics for auto bed level detection sorted -a mixture of opto (for level detection) and mechanical (for endstop safety). Now I can complete the Chimera carriage and duct.
07/07/2015 update: Final testing of the next piece continues. This is a Chimera specific mount with bed levelling and two layer fans. I hope to release this in the next few days.
28/06/2015 Original post: This original work was created to solve my need for a robust, stable, X-carriage mount for my Prusa i3 and e3D Chimera hot end.
Design features include:
4x LME8UU linear bearings
increased linear bearing separation
no cable ties
X-carriage belt requires no cable ties or screws
modular design components and options include:
simple Chimera mount or much more complex one
complex Chimera mount has options for:
cable chain attachment
bed levelling probe
double layer fan
LED lighting under layer fan


I printed mine in PLA.
Marked work in progress only because I'm adding the remaining components as I produce them. Parts posted are fully workable.
This item was not based on any pre-existing work and was created in DesignSpark. Unfortunately the DesignSpark files are too large to upload - Thingiverse refuses to upload them as they are over 500k each, with some nearly 1M!
Other parts designed for my Prusa i3 steel upgrade are:
http://www.thingiverse.com/thing:1959901 (GT2 belt clamp (Prusa Y-axis)
http://www.thingiverse.com/thing:1937232 (Arduino Mega and RAMPS v1.4 case)
http://www.thingiverse.com/thing:1905409 (Prusa i3 steel 10mm upgrade)
http://www.thingiverse.com/thing:1959974 (Prusa i3 Steel Y-axis motor mount)
http://www.thingiverse.com/thing:1991116 (Prusa i3 Steel X-carriage)
http://www.thingiverse.com/thing:1991117 (E3D Chimera / Cyclops mount)
http://www.thingiverse.com/thing:1994413 (dual E3D Thermocouple amplifier board housing)
http://www.thingiverse.com/thing:1090661 (Belt driven Bowden extruder with 1:2.5 reduction)
http://www.thingiverse.com/thing:896676 (enclosure for SevenSwitch FET)
http://www.thingiverse.com/thing:922455 (8mm Z-axis leadscrew bearing holder)
http://www.thingiverse.com/thing:922309 (Z-axis NEMA 17 adjustable endstop bracket)
http://www.thingiverse.com/thing:899607 (cable chain)
https://www.thingiverse.com/thing:2334269 (LCD housing)
https://www.thingiverse.com/thing:2377049 (PSU cover)
https://www.thingiverse.com/thing:2395715 (Chimera & Zesty Nimble drive cable spacer)
https://www.thingiverse.com/thing:2407651 Chimera Zesty Nimble X-axis set for i3 clone
These are all listed on the Group page I have created for this project http://www.thingiverse.com/groups/prusa-i3-steel-upgrade-project Please feel free to add comments or suggestions there.
For avoidance of doubt, this item is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License. See http://creativecommons.org/licenses/by-nc-sa/4.0/ for more details.