Introduction
Product Page
This Guide relates to this Prusa i3 MK2.5S / MK3S Upgrade Kit:
https://www.bondtech.se/en/product/prusa...
Acknowledgements
This is a co-development work with some awesome guys in the Prusa Community like Chris Warkocki, Grégorie Saunier (Bear Upgrades), Olof Ogland, Erik Bjorgan, Josh Jones, Kyle Wiehe, Marc Evertz, Matt Harrison, Ocie Ward, Sando Bendig, Vecko Kojchevski (Vecko Extruder), and last but not least Steven Mölby that have provided excellent feedback and suggestions of how to develop the "perfect" extruder setup for the Prusa series printer. A lot of work has been spent in this project and we have tried to listen to all the inputs in order to find a solution that can be fitted to a Prusa i3 MK2, MK2S, MK2.5, MK2.5S. MK3, and MK3S.
Introduction
This kit contains the necessary parts to convert to our freshly designed extruder that uses 3:1 gearing ratio for improved precision and resolution, optimized geometry for the heat-sink cooling and many other improved features. It also reduces the moving weight to reduce vibrations and ghosting.
Compatibility
The upgrade is compatible with the following machines:
Prusa i3 MK2.5S |
Prusa i3 MK3S |
Additional Information
The pictures in this guide is captured using a MK3s printer but can be applied to MK2.5S, with the exception of connecting the cables to your board. Please check Prusa's electronics guide on how to connect the cables on your specific board.
Before Performing The Installation
Before installing your MK2.5S/MK3S Upgrade Kit, make sure you first performed the Strip Reusable Parts procedure which Guide you can find here:
02. Prusa i3 MK2.5S / MK3S Upgrade Kit - Strip Reusable Parts
Recommendation
Download and print out Bondtech’s PTFE cutting fixture for precise measurement of the tube length. STL file can be downloaded using the link in the Parts section below.
You will need :
Tools
Parts
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Heater Block Cable
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Thermistor Cable
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Check if the Shaft Assembly is attached to the Housing that bears the Stepper Motor.
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Check if the Hinge Shaft is attached to the Housing that holds the Hinge.
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Part supplied in the Bondtech upgrade kit: Lever.
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Parts stripped from the MK2.5S / MK3S: Short Magnet; Long Magnet; Secondary Drive Gear; M3x18 Screw.
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Insert and press fit the Short Magnet in the Lever;
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Insert the M3x18 screw in the screw hole of the Lever.
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The Magnet Lever will be placed here with its screw aligned with the hole.
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Tip of the screw to the bottom; screw to the left; magnet to the right.
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Screw the Magnet Lever all the way in and then loosen it a bit (half of a turn) so it can rotate freely.
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Part stripped from the MK2.5S / MK3S: Long Magnet.
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Insert the Long Magnet in this slot, all the way in.
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Use an orientation that repels the Magnet Lever.
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If the Magnet Lever is repelled, the Long Magnet was inserted with the correct orientation.
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Part stripped from the MK2.5S / MK3S. Secondary Drive Gear.
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The Secondary Drive Gear will be placed in the Hinge with its axis aligned between the slot and the hole.
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Lay down the Gear's shaft in the slot with the gear large teeth on the side of the slot.
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First press the shaft into the slot, then push the shaft into the back hole until it's flush to both outer faces of the Hinge.
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Parts stripped from the MK2.5S / MK3S: Primary Drive Gear; Square Nut.
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The Primary Drive Gear will be placed on the Main Shaft with the Set Screw aligned with the flat face of the Shaft.
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The Square Nut will be placed in the marked slot.
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Press fit the Square Nut until it flushes to the Housing face.
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Slightly fasten the Primary Drive Gear Set Screw.
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Part supplied in the Bondtech upgrade kit: PTFE Tube.
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Part stripped from the MK2.5S / MK3S: Hotend Assembly.
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Part we recommend you to 3D print: Cutting Fixture.
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Use the Fixture's groove to guide the Cutting Tool.
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Parts supplied in the Bondtech upgrade kit: PTFE Tube; Collet Clip.
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Part stripped from the MK2.5S / MK3S: Hotend Assembly.
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Insert the PTFE Tube in the Hotend all the way in.
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While inserted, cut the PTFE Tube at 6,30mm from the Hotend's metal face.
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Insert the Collet Clip between the Hotend's metal face and the Push-Fit to hold the PTFE Tube in place.
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Part supplied in the Bondtech upgrade kit: Posterior Housing Half.
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Part stripped from the MK2.5S / MK3S: Hotend Assembly
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If you are using a Bear X-Carriage remove the hex plug and install a M3 Nut before installing the Hotend.
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Insert the Hotend in the Housing at an angle, PTFE Tube first.
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After fitting the top of the Hotend, drop the Heat Block down into place.
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The Main Shaft's tip must align with the bearing hole inside that rounded hole.
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The head of this screw goes into that rounded groove.
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The Hinge shaft must align with the matching hole.
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Hold the Extruder with the Hinge facing you.
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Use an Hex-key to check the alignment.
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Tighten the screw. Ensure the screw is fully set in the drive gear and towards the flat surface of the shaft.
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Part supplied in the Bondtech upgrade kit: 1x Square Nut.
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Parts stripped from the MK2.5S / MK3S: 4x Square Nut.
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Part we asked you to 3D print: X-Carriage R2 Front.
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Identify the 5 Nut Slots.
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Insert each Square Nut into a Slot.
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Press them in until they flush to the X-Carriage body.
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Parts supplied in the Bondtech upgrade kit: Extruder Housing; 1x Square Nut.
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Part stripped from the MK2.5S / MK3S: Hotend Assembly.
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Find the Nut Slot near the Hotend.
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Insert the Square Nut inside.
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Press it all the way inside.
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Parts supplied in the Bondtech upgrade kit: Extruder Housing; 3x M3x40 Screw.
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Part we asked you to 3D print: X-Carriage R2 Front.
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Use a M3x40 Screw to attach here.
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Use a M3x40 Screw to attach here.
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Use a M3x40 Screw to attach here.
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Parts supplied in the Bondtech upgrade kit: Stepper Motor; Stepper Motor Cable.
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Plug the Stepper Motor Cable in the Stepper Motor white socket using the white plug.
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Parts supplied in the Bondtech upgrade kit: 4x M3x12 Screw;
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Part stripped from the MK2.5S / MK3S: Axial Fan With Cable.
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Guide the Stepper Motor Cable through the groove of the Extruder Housing.
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Locate and find the 4 Housing holes to attach the Axial Fan.
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Attach the Fan to the Housing using the 4 M3x12 screws.
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Place the fan so the Axial Fan Cable follows this path.
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Parts supplied in the Bondtech upgrade kit: Radial Fan Holder; 2x M3 nuts.
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Press fit the Nuts into the Radial Fan Holder.
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Parts supplied in the Bondtech upgrade kit: Radial Fan Holder; M3x10 Screw.
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Find the Housing's embedded nut.
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Screw the Fan Holder into place.
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Parts supplied in the Bondtech upgrade kit: Radial Fan Holder; M3x10 Screw.
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Find the Housing's embedded nut.
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Screw the Fan Shroud into place.
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Parts supplied in the Bondtech upgrade kit: 2x M3x20 Screw;
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Part stripped from the MK2.5S / MK3S: Radial Fan With Cable.
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Find the Radial Fan Holder embedded nuts and align them with the Fan fixation holes.
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Orient the Fan's outtake into the Fan Shroud intake.
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Screw the Radial Fan into place.
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Route the Fan Cables using the grooves on the side of the Housing.
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Parts supplied in the Bondtech upgrade kit: M3x16 Screw;
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Part stripped from the MK2.5S / MK3S: PINDA Probe with cable
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Locate the Probe holder in the Housing.
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Slide the Probe through the Probe Holder and over about 5mm.
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Use the M3x16 Screw to tighten the Probe in the Holder.
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Route the Probe's cable as show in the picture.
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Part supplied in the Bondtech upgrade kit: Steel Ball Holder
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Part stripped from the MK2.5S / MK3S: Steel Ball.
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Place the Stell Ball in the Stell Ball Holder.
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Locate the Holder's slot in the Housing.
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Press fit the Holder and Steel Ball into place.
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Use 10 to 15 cm of 1,75mm filament to perform this Quality check.
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The Magnet Lever test looking through this top window.
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The Stell Ball test looking through the Hinge window.
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While inserting the filament through the filament intake of the extruder, the Magnet Lever should:
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Move away when the filament enters.
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Move back when the filament exits.
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With this test we check if the Drive Gears are aligned with the Filament Path.
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Pass through the Filament Sensor Steel Ball
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Reach the Primary Drive Gear, while you watch through the Hinge Window, and align with its teeth as show in the video.
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Part stripped from the MK2.5S / MK3S: Filament Sensor PCB; Filament Sensor Screw; FIlament Sensor Cable.
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Put the PCB in place and tighten it with the Screw.
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Plug the cable in, using the connection plug to grab the metal terminals of the PCB.
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Parts supplied in the Bondtech upgrade kit: Filament Sensor Cover; M3x10 Screw;
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Put the Cover in place.
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Screw it in using the M3x10.
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Part supplied in the Bondtech upgrade kit: Thumb Screw;
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Insert the Thumb Screw into the Hinge hole.
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Tighten it all the way in and then release it 2 to 4 full turns.
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Part supplied in the Bondtech upgrade kit: 2x Black Zip Tie
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Locate in the X-Carriage the holes to guide the Zip Ties.
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Inserting and push them through minding the orientation of the lock.
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Position the extruder on the Print Bed and align both Zip Ties with the sliding block's grooves.
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Attach the Extruder to the Linear Guide's Sliding Block.
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Place the Drive Belt in the bottom horizontal groove of the X-Carriage R2.
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Tighten the Zip Ties.
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Clip both ends of the Zip Ties
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These Screws fix or release the X-axis Stepper Motor.
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This screw changes the distance to center of the Stepper Motor.
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Release the Stepper Motor.
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Move the stepper Motor closer to the Extruder to loosen the Drive Belt, before placing both ends of the Drive belt in the X-Carriage
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Move the stepper Motor away from the Extruder to thighten the Drive Belt, after placing both ends of the Drive belt in the X-Carriage
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Check the Drive Belt's tension before fixing it in position.
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Tighten the Stepper Motor after finished positioning it.
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These grooves in the X-Carriage R2 will hold the Drive Belt in place.
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Place one end of the Drive Belt in one X-Carriage's drive belt grooves.
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Place the other end of the Drive Belt in the other X-Carriage's drive belt groove.
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Increase tension in the Drive Belt and fix the X-Axis Stepper Motor at that position to finish this step.
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Part stripped from the MK2.5S / MK3S: M3 Nut.
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Part we asked you to 3D print: X-Carriage R2 Rear.
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This is where the M3 nut will be placed.
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Press fit the M3 nut in position.
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These cables will cross the X-Carriage Rear in the next step.
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Stepper Motor Cable
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PINDA Probe Cable
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Radial Fan Cable
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Axial Fan Cable
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Pass the Main Cable Guide through the X-Carriage Rear.
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Insert the tip of the Main Carriage Guide
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In the bottom center hole of the X-Carriage Front
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Use these 5 M3x10 Screws...
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And these 5 holes of the X-Carriage...
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To attach it in place.
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Grab the Heater and Thermistor Cable Holder
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And orient its screw to this hole in the X-Carriage Rear.
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Then Screw the holder in with this screw.
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Parts supplied in the Bondtech upgrade kit: 3x Zip Tie
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Part stripped from the MK2.5S / MK3S: Main Cable Sleeve
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Roll the Sleeve around the cables
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And pass the Zip Ties through the Heater and Thermistor Cable Holder using these 3 holes.
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Tighten the Zip Ties.
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Cut the Zip Ties tips
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As short as possible
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Wrap the Main Cable Sleeve around the cables starting from the fixed tip...
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up until there is no more Sleeve to wrap.
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Plug for Heater Cable
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Plug for Axial Fan Cable
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Plug the Heater Cable in.
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Plug the Axial Fan Cable
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Plug the Radial Fan Cable in.
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Plug the Filament Sensor Cable into the bottom Row!
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Placing the Single wire to the left.
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Plug the thermistor Cable in.
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Plug PINDA Probe Cable in.
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Plug Stepper Motor Cable in with the black wire on top.
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Place the Sleeve tip slightly crossing the Main Cable Port.
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and route the cable to allow the Control Box to close.
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Use the Main Cable Half Ring...
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to secure the Main Cable in Place by screwing it to the other Half Ring in the Control Box.
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Close the Control Box Door
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Fasten the Control Box Door with this screw on the opposite side of the Control Box.
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Lower the Print Head by rotating the lead screws of the Z-axis...
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... until the nozzle touches the Build Plate
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Loosen the PRINDA Probe by releasing pressure on the Holder.
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Let the PINDA Probe slide down until it reaches the Zip Tie.
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After the Probe is in position, tighten the Holder back on by fastening the screw.
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Part supplied in the Bondtech upgrade kit: Powered By Bondtech Sticker
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If you like, place the sticker on your MK2.5S / MK3S at a place of your choosing.
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