DIYElectronics PRUSA I3 User manual

Prusa i3 Enclosure Build Guide

Contents
[1] Preparing your printer for the enclosure......................................................3
[1.1]Cable
Management.....................................................................................3
[1.2]
Calibration.............................................................................................
......3
[2] Floor and Side Panels....................................................................................4
[2.1]Floor & Side Panels
Placement..................................................................5
[2.2]Rubber
Feet................................................................................................5
[3] Perspex Side Panels.......................................................................................6
[4] LCD Panel & USB Panel Mounting................................................................7
[4.1]LCD panel
Mounting...................................................................................8
[4.2]USB panel
Mounting...................................................................................8[5]
Printer
Placement...........................................................................................9
[6] Fan Mounting & LCD Connecting................................................................10
[6.1]Fan
Mounting.............................................................................................1
0
[6.2]LCD
Connecting........................................................................................11
[6.3]USB
Connecting........................................................................................11

3
[7] Roof Panel
Assembly....................................................................................12
[7.1]Filament Feeder
Assembly........................................................................13
[7.2]Handles..................................................................................................
...13
[8] Front Door Assembly....................................................................................14
[8.1]Door
Hinges...............................................................................................15
[8.2]Door
Magnets............................................................................................16
[8.3] Door
Knob.................................................................................................16
[9] Spool Holder & Cable Clips..........................................................................17
[9.1]Spool
Holder..............................................................................................17
[9.2] LCD Cable
Clips........................................................................................17
Benefits................................................................................................................18

Before you get started with building the enclosure, there are a few
preparation steps to be done in order to get your Prusa i3 printer neat,
calibrated and ready to be placed within the enclosure.
[1.1]
Wiring
Cable management is
extremelyimportant so that
cables dont get in the way
and get damaged or broken
• Make sure cables are neat
and tidy with use of cable
wrap and cable ties
*Especially around the
RAMPS board
See photo examples of neat
cable management
[1.2]
Calibration
• Run a calibration test print on
your printer to ensure your
printer is well calibrated and
running smoothly before you
place it in your built enclosure
Make sure everything on your printer is neat, tightened, adjusted
and calibrated before you put your printer into the enclosure.
This is to avoid issues and to ensure everything will run smoothly.
[1]
Preparing Your Printer
*
*
You may cable tie this up once the printer is in the enclosure so that
it does not interfere with the bed moving back and forth when printing

5
[2] Floor and Side Panels
Materials needed:
Aluminium floor
panel
1
Rubber feet
4
Aluminium front
panel
1
M5 x 16 screws
11
Aluminium back
panel
1
M5 washers
7

6
[2.1]
Floor & Side Panel Placement
• Lay down bottom floor panel
• Place the front & back panels on
front and back side of the floor panel
• Screw M5x16 screws into all 4
corners with washers, loosely
[2.2]
Rubber feet
• Flip enclosure onto back panel
• Screw in rubber feet, finger tight

7
Perspex side
panels
M3 x 16 screws
2
Thumb Screws
8
8
• Line up and screw in perspex sides
with M3x16 screws and thumb screws onto
each side of the enclosure
• You can tighten these screws up a fair
amount, just be careful not to crack the
perspex
[3]
Perspex Side Panels
Materials needed:

8
M3 x10 screws
2
USB panel mount
cable
M3
Washers
2
1
[4]
LCD Panel & USB Panel Mounting
Perspex LCD
piece
LCD screen
(
)
Standard or graphical
➢Plastic
spacers
M3 x 10 screws
M3 x 20 screws
M3 nuts
4
4
8
1
1
8
Materials needed:
LCD Panel Mounting
Materials needed:
USB Panel Mounting
➢Depending on the LCD Screen you have chosen the spacing size
will vary. Your kit will include 8 spacers.

9
[4.1]
LCD Panel Mounting
*
Note
the LCD panel shown in this guide is a
graphical LCD panel, you may have a standard LCD
panel depending on your specification, but the
assembly is the same
• Lay perspex flat, insert
M3x20 screws and spacers
into perspex
• Mount perspex to LCD
• Secure with M3 nuts
• Mount LCD from the inside
of the enclosure using M3x10
screws
• Secure with M3 nuts
[4.2]
USB Panel Mounting
• Place the USB cable from the inside
through the small hole at the back
• Screw in using M3x12 and M3
washers.

10
• Place printer inside enclosure
• Place printed fasteners over
rods underneath the printer
• Secure with M5x16 screws,
washers and nuts
M5 x16 screws
4
Prusa i3 printer
Plastic printer
holders
8
M5 washers
8
M5 nuts
8
1
[5]
Printer Placement
Materials needed:

Plastic fan shroud
60
mm fan
Aluminium fan
panel
M3 x 10 screws
M3 x 30 CS
screws
M3 nuts
4
4
4
1
1
1
Fan Mounting
[6.1]
• Place fan on top of fan shroud
* Make sure the fan is orientated such that it blows
into the shroud and enclosure
• Place the aluminium panel on
top of the fan and fan shroud
* Make sure holes are lined up
• Screw in M3 x 30 CS screws,
secure with M3 nuts, tighten
Fan Mounting & LCD Connecting
[6]
Materials needed:
10

12
[6.2]
LCD Connecting
• Connect LCD To RAMPS
board with LCD leads
[6.2]
USB Connecting
• Connect the USB panel mount
to USB socket on RAMPS board
• Secure with M3 x 10 screws
• Connect fan to RAMPS aux
12V connector
• Turn enclosure around so the
back is facing frontward
• Place fan mount and cable
through hole at the back of
the enclosure

13
M5 washers
4
Plastic handles
M5 x 30 screws
4
2
Aluminium roof
panel
Plastic filament
feeders
M3 x 10 screws
M3 nuts
M5 x 16 screws
M5 washers
4
6
6
1
2
4
[7]
Roof Panel Assembly
Materials needed:
Filament Feeder Assembly
Materials needed:
Handles

14
[7.1]
Filament Feeder Assembly
• Lay roof panel upside down
• Place smaller and bigger
filament feeder pieces on the
inside of the roof panel
*Line up holes as seen in picture
• Screw in M3x10 screws,
tighten with M3 nuts
(from the outside)
• Place roof panel on top of the
enclosure
• Secure with M5x16 screws
on all sides
*leave these screws a little loose
until right at the end
[7.2]
Handles
• Place handles on top of roof
panel
• Use washers and M5x30
screws to secure

15
[8]
Front Door Assembly
M5 nuts
2
Printed door
hinges
M5 x 50 screws
2
M4 x 16 screws
4
4
M4 x 12 screws
M4 nuts
4
M4 washers
4
M3 washers
4
2
Perspex front
door piece
1
M3 nuts
6
Printed magnetic
latches
M3 x20 screws
6
4
Materials needed:
Magnetic latches
Materials needed:
Door Hinges

16
[8.1]
Door Hinges
• Assemble the two parts
of the printed hinges using
M5x50 scews and nuts
* Don’t tighten these too much as it will
be diffiuclt to freely open the door
• Attach hinge to perspex
with M4x12 screws M4 nuts
and washers
• Attach the door to the enclosure
at hinges with M4x16 screws
* Before tightening these screws, make sure the
doors line up and do not catch on the enclosure.
Once the door is correctl aligned, you may tighten
the screws
M4 nut
1
b
Printed door kno
M4 x 16 screw
1
M4 washers
1
1
Materials needed:
Door Knob

17
[8.2]
Door Magnets
• Attach perspex magnet to the
inside of the perspex on the
top right corner using M3x20
screws, nuts and washers
* Please note top and bottom magnets are
labelled in seperate packets, do not get
these mixed up
• Attach enclosure magnet to
the inside of the enclosure on
the top right corner using an
M3x20 screw and nut
• Repeat these steps for the
bottom, make sure the inside
magnets line up with the
outside magnets
[8.2]
Door Knob
• Insert M4x16 screw into the
door knob
• Fasten onto perspex using
an M4x16 screw, nut and
washer
* Do not overtighten to avoid cracking the
perspex

18
[9.1]
Spool Holder
• Insert nuts into spool holder
• Line up and attach spool
holder to inside of enclosure
using M4 screws and nuts
* Note there are holes on both sides of the
closure should you want to print a second
spool holder
LCD Cable Clips
[9.2]
• Attach clips to the inside of the
roof using double sided tape
* Place one clip towards the front left side and
the other towards the back, as shown in the
picture
• Feed LCD display cables
through the clips on the roof
M4 x12 screws
2
Printed spool
holder
M4 nuts
2
M4 washers
2
Printed cable
clips
2
1
Spool Holder & LCD Cable Clips
[9]
Materials needed:

19
•
Tighten up the screws that were left a bit loose during the build, namely
the M5x16 screws used to asseble the panels together.
•
Remember not to overtighten the screws that fit into the perspex or it
will crack.
Do not hesitate to contact as should you run into an issue or have any questions!
[e-mail]
You are now finished building your Prusa i3
enclosure! We hope you enjoyed this build and
furthermore will enjoy the great benefits that
this enclosure will provide.
Benefits:
-
Reduces warping
-
Helps control printer fumes
-
Improves overall quality of prints
-
Reduces noise
-
Easily portable
-
Drys out old filament (acts as a dehumidifier)
-
Looks awesome! :D