The printer that makes itself

RepRap 3D printer

Technical data:

What was needed: A 3D printer that can produce its own essential parts quickly and accurately
Requirements: High precision and working speed, no vibration, lightweight, lubrication-free, low friction
Products used: drylin® linear guides, dryspin® lead screw drives and flanged trapezoidal lead screw nuts, stepper motors
Success for the customer: With the xBot, Benjamin Krux is targeting demanding private users as well as schools, universities and industry: "The printer is not only fast and precise, but also high-quality and durable. It can process various materials - from compostable PLA and the standard material ABS to flexible materials such as nylon and rubber-like plastics. The construction is solid and all the main components are manufactured in Austria or Germany."

3D printing with precision and high speed - and with igus linear guides

RepRap xBot: The printer that makes itself
The xBot from RepRap Austria is a 3D printer that can not only produce essential parts of itself. It prints very precisely and quickly using the principle of fused deposition modelling (FDM). Components from the igus drive system make an important contribution to this.

The RepRap brand has a special reputation in the rapidly growing 3D printer market. This is because RepRap is not a manufacturer or a company, but - if you like - an "open source" project or a basic design that is freely available on the internet and is intended to be used by as many users as possible.

The idea came from the English professor Adrian Bowyer. In 2006, he developed a 3D printer that can produce the plastic parts required for its construction itself: the self-replicating printer or "Replicating Rapid Prototyper", RepRap for short. He published the design data and drawings on the Internet. His aim was to get as many users as possible to build the 3D printer and develop it further.

This unusual concept has been a success and continues to spread. As a result, although the RepRaps in different countries use the same basic structure, their characteristics are quite different.

xBot from RepRap Austria: Fast and highly precise
The second generation of the xBot developed by Benjamin Krux/RepRap Austria impresses at first glance with its solid aluminium housing with a perfect finish. More important, however, are the precision and working speed, and both are remarkable, as the developer explains: "The xBot prints with an accuracy of up to 2/100mm. In practice, however, a build-up of 1/10mm thick layers is usually sufficient. And because we have minimised the weight of the moving parts, the printer achieves a very high speed without vibrations."

In addition to the low weight of the print head, this is also due to the high-quality drive technology and the strong, high-precision guide of the print head and print bed. In the X and Y-axis, igus linear guides are used, and two parallel lead screw drives from the igus drylin product range, which are driven by stepper motors, ensure precise positioning of the print bed in the Z-axis.

Drive components from the igus modular system Benjamin Krux selected drylin JFRM flanged trapezoidal lead screw nuts with a 10x2mm trapezoidal lead screw.The trapezoidal lead screw nuts are made of the iglidur J high-performance polymer, which has excellent sliding properties and very low friction thanks to its "built-in" lubricant. This drive concept provides the best conditions for vibration-free, fast travel and precise positioning.

Non-driven guides are installed at the four corner points of the print bed, and concealed drive elements from the igus modular system are also used. The vertical guides for the heating bed travel on drylin R linear plain bearings of type RJUM-01, in which a closed anodised aluminium adapter with standard dimensions for recirculating ball bearings is combined with a liner made of iglidur J.

With the xBot, Benjamin Krux is targeting both demanding private users and schools, universities and industry: "The printer is not only fast and precise, but also high-quality and durable. It can process a variety of materials - from compostable PLA to standard ABS to flexible materials such as nylon and rubber-like plastics. The design is solid, and all major components are made in Austria or Germany."

Despite this high quality standard, part of RepRap's self-image is to offer affordable 3D printers, after all, the idea is for many users to benefit from the advantages of generative manufacturing. This is another reason for Benjamin Krux to use igus components and other cost-effective standard supply parts. Incidentally, he got to know the company almost on site, at the "Automation" trade show in Linz. RepRap Austria's headquarters is only 30 kilometres away in Neuhofen/Krems.

"3D printers will be used in the same way as PCs."
With the design and positioning of the xBot as a high-quality and solid, yet cost-effective 3D printer, Benjamin Krux has met with lively demand. He has currently equipped an "open technology lab", which several schools in Vorchdorf/Austria have set up, with eight xBots. He is convinced: "In a few years, 3D printers will be used in the same way as PCs are today."

A relatively new business segment of igus will then also benefit from this. The high-performance polymers from the iglidur product range are available as filaments that can be processed by 3D printers such as the xBot into construction elements in customised shapes.

Products used

Further 3D printing applications

Cleanroom 3D printer

What was needed: A precise and reliable cleanroom 3D printer for processing thermoplastics
Requirements: Absolutely lubrication-free and maintenance-free, high service life, suitable for cleanrooms, no abrasion, cost efficiency
Success for the customer: Design freedom was gained on all linear guides by utilising the drylin® bearing with exchangeable liners. This has significantly accelerated the design process. The liners prevent unwanted particle release and at the same time offer process stability. The use of suitable rail and shaft guides brought additional advantages in the realisation of the system.

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Portable 3D printer

What was needed: A compact, portable 3D printer that can still produce detailed 3D parts
Requirements: Top performance even in tight spaces, no maintenance, 100% lubrication-free, low wear and friction, smooth dry operation, no noise or vibration, no dust or dirt adhesion
Success for the customer: In developing countries and distressed areas, a portable device with high precision is very helpful. It is a radical step forward for dental and medical care. The igus® products in the 3D printer ensure a long service life, clean printing conditions and dry operation without vibration or noise.

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Fabforge Innovations 3D printer

What was needed: A precise and quiet 3D printer that fulfils the conditions for "Made in India"
Requirements: 100% lubrication and maintenance-free, precise, quiet and vibration-free operation, smooth dry operation

Success for the customer: Fabforge Innovations is a manufacturer of 3D printers based in South India and operates across the country. It used to use linear rails from other manufacturers, but to meet the "Make in India" conditions, Fabforge Innovations changed the design and used igus® products.

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3D printed lead screw nut

What was needed: An alternative to metal ball screw nuts that can be manufactured independently using 3D printing
Requirements: 100% lubrication and maintenance-free, quiet operation, easy to manufacture, smooth running, clearance-free
Success for the customer: The design allowed no other way to achieve the set goal. The parameters were prescribed and the final product had to work. Optimising the contact area was crucial to reducing friction. Thread surface hardening reduced it further. After several printing attempts, the print quality was able to be improved.

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Mini 3D printer

What was needed: A compact and cost-effective mini 3D printer
Requirements: During printing, a tray must perform extremely precise vertical movements in order to achieve a high print resolution of 50 micrometres. In addition, the smallest possible components had to be found for the compact 3D printer.

Success for the customer: With the help of drylin components, it was possible to develop the Lumi Pocket, a 3D printer that combines an extremely compact design with outstanding print quality and an unbeatable price.

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Office 3D printer

What was needed: A precise, large-format 3D printer suitable for use in offices or workshops
Requirements: Maintenance-free, easy installation, high accuracy, 100% lubrication-free, no dust and dirt adhesion, quiet and vibration-free due to office use
Success for the customer: The engineers use linear guides, carriages, and dryspin® type lead screws and lead screw nuts for the linear movements of all three axes. The lead screws allow travel speeds of up to 120mm/s. All components help to minimise maintenance of the 3D printer. The right 3D printer for the office.

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