Wanhao Duplicator i3 3D printer
[R1] maintains four Wanhao Duplicator i3 3D printers for production FDM fabrication. Each printer has been upgraded with a controller and installed on a printer cart
ReDuplicator Upgrade
Part Description Number Reqd 3030 Extrusion 355mm Z Axis HFSLB6-3030-355 2 3030 Extrusion 350mm Y Axis HFSLB6-3030-350 2 3030 Extrusion 380mm X Axis Tower HFSLB6-3030-380 2 3030 Extrusion 258mm X Axis Base HFSLB6-3030-258 2 30x30x35 Corner Brackets Tabbed on SINGLE Side only HBLFSNB6 14 Alluminium Flat bracket 4 mount holes HPTLS6 8 LM8UU Bearings Std 8mm 15mm long bearings LMU8 4 M5 12mm Button Head Screw M5 70 M5 16mm Button Head Screw M5 10 M5 T-Nuts 3030 T-Nuts Drop in preferred 80 M5 20-25mm Low Profile Button head (less than 4.2mm) 1 M5 30-35mm Screw M5 1 M3 Heatserts Brass heat inserts M3 thread M3-UHBRHESF 22 M3 4-8mm Button Head Screw M3 8 M3 12mm Button Head Screw M3 6 M3 16mm Button Head Screw M3 6 M3 30mm Screw M3 3 M3 6-8mm Countersunk M3 4 M3 6-12mm Countersunk M3 8 M5 Nylock Nuts for Idlers 2 M3 Nylock Nut for part cooling and heat sert substitute 1 - 15 M5 Smooth Idler Pulley (Optional) 9mm wide replacement 2 M5 Fibrous Washers For idler Pulleys 3 - 10 GT2 Belt 6mm belt 1m 50mm Blower Part Cooling 1 M3n Square nut X motor tensioner (optional) 2 In Depth Descriptions:
A Wanhao i3 Duh! (these parts will also allow you to upgrade most other prusa style printers, just adjust the lengths of your printer compared to the Wanhao’s smooth rods (X=320mm Z=320mm Y=380mm)
Various 3030 T-slot Aluminium Extrusions
2x 380MM - Tower X - HFSLB6-3030-380
2x 355MM - Tower Z - HFSLB6-3030-355
2x 350MM - Base Y - HFSLB6-3030-350
2x 258MM - Base X - HFSLB6-3030-258
14x Corner Brackets 30x30x25 - Importantly these should be reversible or only be tabbed on one side! We are stacking two extrusions perpendicular on top of eachother. If they are fully tabbed on both sides they will NOT fit. HBLFSNB6 with low profile T-nuts or the single tabbed version HBLFSNK6.
8x Aluminium Corner plates with 4 mounting holes. The legs and printed corner parts are all based on the misumi hole spacing HPTLS6.
4x LM8UU Bearings. These replace the stock Z bearings. It is also worthwhile purchasing some of the longer LM8LUU bearing to replace the X and Y axises if you are coming from a pre 2.1 wanhao. These misumi ones are much higher quality than the originals. LMU8, LMUW8.
70x M5 12mm Button head screws
10x M5 16mm Button head screws
80 M5 T-Nuts. Drop in T-nuts are recommended as they are easier to work with. Some drop in T-Nuts have a longer neck which can cause issues with the Misumi HBLFSNB6 corner brackets. One side of the bracket is protruded, so that even when screwed in very tightly they don't apply enough compression force to secure the frame. In this case 14 T-nuts can be substituted with flat style ones, or pieces of fibre washers can be glued into the grooved areas to reduce the protrusion depth. Misumi also have t-nuts designed specifically for this bracket HNTT6-5. 14 of these can be used.
Tnut mod for corner brackets protrusions
1x M5 20-25 mm Button Head screw (low profile) The head needs to be 4.2mm or less long as this sits between the idler part and the leadscrew.
1x M5 30-35mm screw
22x M3 Heat-sert Brass inserts (M3-UHBRHESF) W4.4mm x H5.8mm or similar. These are set into parts using a hot soldering iron and are great for making strong functional parts without having to worry about screw threads stripping over time. Proper thermal inserts are recommended, but the easier to source injection molding type ones should work almost as well.
7x 4-8mm M3 Button head
6x 12mm M3 Button head
6x 16mm M3 Button head
3x 30mm M3 screw
4x 6-8mm M3 countersunk
8x 6-12mm countersunk (for leadscrew nuts) you also may want to secure these with nylocks m3 x8
2x M5 Nylock nut
1x M3 Nylock for part cooling bracket. 6 more can be used as a substitute for the extruder assembly if Heat-serts cannot be found.
Some fasteners are carried across from the Wanhao. This includes the hotend screws, and the M4 x-carriage screws.
(Optional) 2x M5 Smooth Idler Pulleys. The original Wanhao pulleys are prone to failure over time and are 11mm wide. i recommend switching them out with new ones while doing this mod. Most replecement ones are 9mm wide which allows you to use the X Gantry Idler 9MM part instead of the X Gantry Idler 11mm (Stock idler) part. The 9mm version has thicker walls which should make it more durable over time.
3-10 M5 washers (Steel or fibrous). Used to secure the X and Y idlers. Variable number required depending on their thickness and whether you are using stock idlers or the usually thinner aftermarket ones.
1 Meter of GT2 6mm belt. The X carriage distances are increased and the stock belt may not be long enough. aprox 770mm is required.
50mm Blower Fan. Hopefully you should already have one of these in your arsenal as they make a huge improvement to print quality
Fasteners required Summarised Misumi Parts List
HFSLB6-3030-355 2 HFSLB6-3030-380 2 HFSLB6-3030-350 2 HFSLB6-3030-258 2 HPTLS6 8 HBLFSNB6 14 LMU8 4
Notes: Substitute with HFSL6-3030 if you would like non anodized silver HFS-3030 (Standard) or any other type of 3030 can be substituted instead. Essential Tools
Set Square, ruler, measuring tape. - to ensure everything is a flush 90 degrees Xacto Knife to clean prints, especially screw holes soldering iron to insert the brass heat-serts
