Getting Started: Ordering Materials for The Frame

So, last time I gave my reasons for selecting the MendelMax design.  This time I'll cover how I acquired framing components.

Shortly after settling on the basic design, I wanted to get this build started so I began the search for a supplier of frame components.  I started with McMaster-Carr (I've bought from them before for work-related stuff), and I even made a spreadsheet to optimize my ordering of their pre-cut extrusions.

Here is where I made my first mistake:  I bought a chop saw from Harbor Freight for cutting extrusions to length, thinking I would be buying from McMaster-Carr and cutting my own.  The day after doing this, I discovered Misumi's website, and read a lot of recommendations on MendelMax.com stating their prices were unbeatable (they are) and they cut stock to ordered lengths.  Yup, I'd just bought a tool I wouldn't be using on this build.

This wasn't the end of the world, and I'm sure I'll be using the saw for future builds, so all is not lost, but that money would have bought a whole lot of fasteners, washers, and other fiddly bits.  The point here is that I rushed in when I should have done just a bit more reading.

As I got closer to go-time, Tony told me, "Hey, when you get ready to order, let me know.  I want to tag along.  This is going to be awesome."

"What?  Are you gonna transplant your Prusa into a Max frame?"  I asked.

"No, man, I just got that working well, and we'll need it to print parts.  I'm gonna build a Max along with ya." he replied, smiling.

I took him at his word, and, after consulting the Trinity Labs and  MTW Build Guides have ordered:

• 8 ea.   20 mm X 300 mm long square t-slot extrusions, black anodized finish.
• 8 ea.   20 mm X 340 mm long square t-slot extrusions, black anodized finish.
• 14 ea. 20 mm X 420 mm long square t-slot extrusions, black anodized finish.
• 200 ea. T-slot nuts, 5mm.

I live just down the road from a Fastenal store, so I figure I'll check locally for cap screws, washers, etc. to complete the frame build.

Tony's printing test parts on the Prusa, so we'll soon have the printed parts for the frames ready.

Yesterday the package from Misumi arrived.  It's still sealed until I get with Tony and we divvy up the goodies.  The entire order shipped for a touch less than $136 and was delivered in five days.

Yeah... this is gonna be awesome.

Beginnings

This whole thing got started when I met a friend at work who already had a 3D printer.  Tony's printer is a Prusa Mendel and he has used it to do some really cool stuff.  Anyhow, talking to him I became intrigued with this technology.

I'd heard of 3D printing, but always thought it to be out of reach economically speaking.  Most of the units I'd seen were selling in the thousands of dollars, and, being an electronics technician by training, I'd often wished I could find a kit and build one.  I didn't give it much more thought until I met Tony.

He steered me toward reprap.org and told me to ask him about anything I saw there.  I warned him I was going to be asking a lot of questions, as I was really fascinated with the idea of an affordable 3D printer.  

As I learned about the open source, maker-driven culture of 3D printing that was growing up around me, I felt that old familiar itch coming back from my days in the DIY electronics hobby long ago.  I knew right then I would be starting this project.

We began an active chatter in email, with me peppering Tony with all sorts of questions about why he chose the Prusa design, what sort of capabilities his printer had, what would he do differently, on and on.  Tony answered my questions candidly, patiently, and in such a way that I began to believe I could do this.

The more we talked and emailed, the more I became convinced I wanted to build a MendelMax design.  What motivated me to choose this design?  There were several features I found compelling:

• The frame of the MendelMax is built from off-the-shelf aluminum extrusions. I already had experience with using extrusions to build things at work.  I liked how it went together quickly, was easy to get squared up, and was light, rigid, and had a nice appearance.  I felt this would make the printer more steady, repeatable, and accurate.
• The design for the MendelMax is robust, and was already mature enough that several iterations of it were in existence. A wealth of data about the design and its various modifications was easily accessible.  (I did not want to be designing my first build from scratch - we'll save that for next time!)
• Parts for the MendelMax are readily available. I didn't feel like having to spend a lot of money for exotic hardware.
• I believed the MendelMax to be the best bang for the buck.  It struck the right balance of price and performance.
• The design is modular.  This meant I could spread out the expenses over the entire build.  It also means that the MendelMax will provide a good testbed for new ideas going forward.

Now you know why I chose this design.  Incidentally, I'll be building some variant of the MendelMax 1.5+, which has a rail-guided Y-axis. 

Next entry we'll look at where and how I acquired the frame components.