My HyperCube Evolution

THIS IS A WORK IN PROGRESS

My version of the HyperCube Evolution, based heavily on the work by Scott_3D and Tech2C. My plans are to feature dual Z axis motors on a smallish 200x200x200mm build volume using 32bit Marling controller board and a direct-drive extruder (probably the E3D Titan Aero).

I have started a new PlayList on my YouTube Channel to walk through each step of the build: https://www.youtube.com/playlist?list=PLJX30NW4d60PdxcPWZcrLxaXvndv3tkGq

And will update this Thingi page with the Printed Parts, Parts Lists, and link to each video as they are produced.

Please refer to Tech2c and Scott_3D Thingi pages for more information on the HyperCube & HyperCube Evolution 3D Printers (referenced in the Remixed From section on this page)

I welcome feedback and suggestions during this process as my goal is to produce a highly accurate, and fast (up to 80mm/s) 3D Printer (within reason :) ).

Part 1 - Building the Frame

YouTube Video: https://youtu.be/bWggeeBoFs8

Purchased Items:

• 4 x 3030 450mm Extruded Aluminum Frame
• 4 x 3030 320mm Extruded Aluminum Frame
• 6 x 3030 310mm Extruded Aluminum Frame
• 20 x Angle (L) Brackets that match the Extruded Aluminum Profile
  Note: Mounting holes are 16mm & 11mm center to inside corner of L bracket
• 40 x m6x10mm Button-head Screws
• 16 x M5x10mm Button-head Screws
• 16 x M5 T-Nuts for 3030 Extruded Aluminum Frames

Printed Items:

• 20 x Vertical Corner Brackets: Corner Bracket 3030M6.stl
  Note: Holes are 13.5-16mm and 11-13.5mm center to corner to accommodate different Angle (L) Brackets
• 8 x Horizontal Corner Brackets : Corner Bracket 3030M5.stl
• 4 x Feet: Foot 100 micron.stl or Foot 200 micron.stl
• 4 x Caps: Cap 100 micron.stl or Cap 200 micron.stl

NOTE: The Brackets, Feet and Caps are designed for my particular Extruded Aluminum Profile, your's might be different (see included diagram)

Part 2 - Y Axis Assembly

YouTube Video: https://youtu.be/iSqgmtMIO4g

Purchased Items:

• 2 x Nema 17 42mm Stepper Motors
• 2 x GT2 Timing Pulley (20 teeth) 5mm bore for 6mm belt
• 4 x M5x10mm Button Head Screw - Mount Stepper Motor Mount & Idler Mount to Frame
• 4 x M5 T-Nut for 3030 - Mount XY Stepper Motor Mount & Idler Mount to Frame - Taken from Corner Brackets
• 4 x M3x20mm Hex Head Screws - clamp Linear Rods to their Printed Mounts
• 4 x M3x8mm Hex Head Screws to Mount Stepper Motor
• 2 x M3x6mm Hex Head Screws to Mount Stepper Motor
• 4 x GT2 Idler Pulley (20 teeth) 3mm bore for 6mm belt Idler Pullies - to Idler Mounts
• 2 x M3x30mm Hex Head Screws for Idler Pullies to Idler Mounts
• 6+ M3 Washers for between Idler Pullies
• 6 x M3 Brass threaded inserts for Stepper Motor Mounts & Idler Mounts
• 2 x 10mm Dia 310mm long Linear Guide Rods
• 4 x LM10UU 10mm Linear Ball Bearings
• 2 x M6x10 (or 8) Grub (Set) Screws - should already be included with the L Brackets

Reused Parts:

• 10 x M6x10mm Button Head Screws - mount XY Stepper Motor Mount & Idler Mount to Frame. Reused from the 6 replaced 3030 M6 Corner Brackets

Printed Items:

• 1 x Left Stepper Motor Mount: StepperMotor Mount Left.stl
• 1 x Right Stepper Motor Mount: StepperMotor Mount Right.stl
• 1 x Left Idler Mount: XY Idler Mount Left.stl
• 2 x Right Idler Mount: XY Idler Mount Right.stl

Part 3 - X Axis Assembly

YouTube Video: https://youtu.be/8U2uHQMUK4k

Purchased Items:

• 2 x 8mm dia x 350mm long linear rods
• 4 x LM8UU 8mm Linear Ball Bearings
• 2 x GT2 20 tooth 3mm bore smooth idler pullies
• 2 x GT2 20 tooth 3mm bore toothed idler pullies
• 4 x m3x30mm hex head screws
• 12 x m3x14mm hex head screws
• 4 x m3 nuts
• 6 x m3x8mm hex head screws
• 4 x m3x12mm hex head screws
• 22 x m3 Brass threaded inserts
• 4 x 3mm x 12mm dowel pins
• 2 x m3 grub screws (set screws) or m3x6mm hex head screws
• 5m Polyurethane GT2 6mm belt

Printed Items:

The following Printed Parts in this segment come unmodified from Scott_3D HyperCube Evolution Thingiverse Page and can be downloaded from his page: https://www.thingiverse.com/thing:2254103

• 2 x Y_Carriage_xDia8_LM10UU_1.0.stl
• 2 x X_End_Stop_Flag_1.0.stl
• 1 x Y_End_Stop_Flag_1.0.stl
• 1 x X_Carriage_1.0.stl
• 4 x Belt_Tensioner_1.0.stl
• 2 x Belt_Clamp_1.0.stl

Modified Printed Items (found on this page's 'Things' tab):

• 2 x Y_Carriage_Clamp.stl - for through screw holes

Part 4 - Z-Axis and Hot-Bed Assembly

YouTube Video: https://youtu.be/WmAdlwzydTA

Purchased Items:

• 1 x 214x214x3mm 24V MK3 Heated Bed
• 2 2020 140mm Aluminum Extrusions
• 2 2020 315mm Aluminum Extrusions
• 4 x 2020 L-Brackets
• 8 x M4 Sets Screws for L-Brackets
• 2 x NEMA 17 42mm Stepper Motors
• 4 x 12mm Dia x 300 Linear Rods
• 8 x LM12UU 12mm Linear Ball Bearings
• 2 x 8mm x 270mm Lead Screw
• 2 x Anti Backlash 8mm Bearings
• 2 x 5mm to 8mm Couplers
• 56 x M5x10 Button Head Screws
• 24 x M5 3030 T-Nuts
• 32 x M5 2020 T-Nuts
• 8 x M3x8 Hex Head Screws
• 8 x m3x12 Hex Head Screws
• 8 x m3x25 Hex Head Screws
• 4 x m3x30 Hex Head Screws
• 12 x m3 nuts
• 8 x m3 Brass Theaded Inserts
• 4 x m3 Nylon Washers
• 8 x m3 Washers
• 4 x m3 bed springs

Printed Items:

The following Printed Parts in this segment come unmodified from Scott_3D HyperCube Evolution Thingiverse Page and can be downloaded from his page: https://www.thingiverse.com/thing:2254103

• 4 x Z_Axis_Bearing_Holder
• 2 x Z_Nut_Brackets
• 2 x Z_Axis_Linear_RailBracket-_Left_1.0
• 2 x Z_Axis_Linear_RailBracket-_Right_1.0

Modified Printed Items (found on this page's 'Things' tab):

• 4 x Bed_Brackets 15mm
  Courtesy of Larry Cluster from Fackbook:
• 2 x 12mm Linear Rod Top Mount 12.40
• 2 x 12mm Linear Rod Top Mount 12.40 (mirrored)

Part 5 - Electronics & Power

YouTube Video: https://youtu.be/zzgPEO7CoHM

Tools:

• DuPont Crimping tool (Example: SN-28B)
• Soldering Iron

Purchased Items:

• 1 x 24V15A Power Supply (215x115x50mm)
• 1 x 6015 12V (or higher) Fan
• 1 x 12864 ReRap Discount Full Graphics LCD Screen
• 1 x Azteeg X5 GT Controller Board
• 1 x 1m 15A Rated wiring for the PWS and PWS to Controller Board
• 1 x 15A Rated Power Socket & Switch with Fuse
• 9 x 15A Rated Type 'O' Cold Pressed Terminals
• 5 x 15A Rated Female Quick Disconnect Terminals
• Pair of 12864 GLCD Ribbon Cables.
• 12 x 2.54mm DuPont Female Jumper Head Connectors (Fan and Ribbon Cables)
• 4 x Stepper Motor Cables
• 12 x 2.54mm DuPoint Male Pin Connectors (Stepper Motor Cables)
• 2mm Dia Heat Shrink Electrical Insulation Tubing (Stepper Motor Connections to Controller)
• 2 x 2.8mm wide Tab & Jacket Cold Pressed Male Connectors
• 4 x M5x10 Button Head Screws and 3030 T-Nuts
• 2 x M3x6 Hex Flat Head Screws (Power Supply Switch Plate)
• 8 x M4x6 Hex Head Screws and Washers (Power Supply to Cover & Controller Case)
• 4 x M3x4(or 5) Hex Head Screws (Controller Mounts)
• 10 x Brass Threaded Inserts
• 4 x M3x8 Hex Head Screws & washers
• 4 x M3x10 Hex Head Screws (GLCD to Case)
• 4 x M5x12 Fan Mounting Screws
• 2 x TMC2130 Stepper Drivers in Standalone Mode (X & Y)
• 2 x A4988 Stepper Drivers (Z and Extruder)

Printed Items:

• 1 x Controller Board Case.stl
• 1 x Controller Board Case Lid.stl
• 1 x LCD Case.stl
• 1 x Power Supply Cover.stl
• 1+ x 3030 Side Caps.stl (Scaled lengthwise to size)

Part 6 - It Prints!

YouTube Video: https://youtu.be/2Ph9MooEZAk

Purchased Items:

• 1 x E3D Aero Titan Extruder 24v (clone - boooooo)
• 1 x 200x200mm PrintBite Print Bed Surface (yay!!)
• 1 x 3A 5V UBEC Voltage Converter (5.5-26V input)
• 1 x Raspberry Pi 3B/3B+
• 1 x USB 2.0 to USB B Cable Double Left Elbow (20cm)
• 1 x HT100K Thermistor for Hot-End
• 1 x 100K Thermistor for Bed
• 3 x 3D Printer Optical Enstops
• 2 x M3x5 Hex Head Screws (for Y and Z Optical Endstops)
• 3 x M5x10 Button Head Screws and 3030 T-Nuts (for Enstops and Flag)
• 1 x M3x35 Hex Head Screw & Nut (for Extruder Mount)
• 2 x M3x8 Hex Head Screws (for Extruder Mount to Extruder Frame)

Printed Items:

• 1 x Extruder Mount.stl
• 1 x Z Optical Endstop Flag.stl
• 1 x Z Optical Endstop Mount.stl
• 1 x Y Optical Endstop Mount.stl

Part 7 - Great Prints!

YouTube Video: https://youtu.be/WLup8gFgH30

Purchased Items:

Fan duct to extruder mount

• 2 x M3x16 Hex Head Screws
• 2 x m3 Brass Threaded Inserts

Fan motor mount

• 2 x m3x20 Hex Head Screws
• 2 x m3 Brass Threaded Inserts

Spool Holder

• 2 x M5x10 Button Head Screws
• 2 x M5 T-Nuts for 3030 Extruded Aluminum

Printed Items:

• 1 x Spool Holder.stl
• 1 x Spool Holder v2.stl
• 1 x Part Cooling Fan Duct.stl
• 1 x Extruder Mount and Cable Constraint.stl

Part 8 - Hemera Extruder!

YouTube Video: https://youtu.be/WEtp-sWl3RQ

Purchased Items:

Hemera Adapter to Hemera Extruder

• 4 x M3x8 Hex Head Screws

Hemera Part Cooling Duct to Hemera Adapter

• 2 x M3x12 Hex Head Screws
• 2 x m3 Brass Threaded Inserts

Fan to Hemera Part Cooling Duct

• 2 x m3x20 Hex Head Screws
• 2 x m3 Brass Threaded Inserts

Printed Items:

• 1 x Hemera Adapter.stl
• 1 x Hemera Part Cooling Duct.stl

Part 8a - MKS & SKR Contoller Board Case v2

Modifed the Controller Board Case to v2 to support the MKS Gen L, MKS SGEN, SKR 1.3 and SKR 1.4 mainboards. All of these boards have the same dimensions and screw hole offsets, so they should all work with this version.

NOTE: I have not yet printed this, but the dimensions are accurate. Also you will need a 'left elbo' USB Type A cable to connect to the mainboard as there is not enough room for a straight connector.

Printed Items:

• 1 x Controller Board Case v2.stl

Purchased Items:

• 4 x m3x5mm Brass Threaded Inserts