OHAI: Open Hardware Assembly Instructions

1 Gather tools and components to build assembly.

Tools required

2.5mm hex driver
1.5mm hex driver
Wire stripper for 20 & 24 gauge wire
Wire crimper for 20 & 24 gauge wire
Scissors to cut Teflon tape
Alignment Rod
Heat sink fixture

Parts required

2.0 mount plate
2.0 nozzle (.35 or .5mm)
Threaded extension
Heater block
PEEK isolator
2.0 Lower plate
2.0 Upper plate
1.1 Backup plate
M3 x 4 Set Screw
3x M3 washer
3x M3 x 35mm SHCS
5x Heat sink washers
4x Low friction PTFE washer
M3 Stainless set screw
4.7 Ohm resistor
100 Kilo Ohm axial thermistor
2x 20-22 AWG Ferrule
2x 16 AWG Ferrule
4x PTFE Insulation 20 AWG, 18mm length
2x PTFE Insulation 13 AWG, 18mm length
2x PTFE Insulation 11 AWG, 18mm length
2x 20 AWG High Temp Wire - Red 180mm
2x 24 AWG High Temp Wire - Orange 180mm
PTFE Tube for 3mm filament 27.5 - 28mm length
Connector housing - male 4 pin
Connector terminal - male 24-30 AWG
Teflon Tape

Tools and components

2 Construct the heat sink

Insert the PTFE tube for filament into the heat sink construction fixture

Slide heat sink washer down the PTFE tube till its flush with the peek isolator

Slide low friction PTFE washer down the PTFE tube till its flush with the heat sink washer

Continue this until there are 5 heat sink washers and 4 PTFE washers stacked on top of each other as shown

Once this is complete, you can remove the heat sink from the peek isolator

PTFE tube, heat sink washer, PTFE washer

Heat sink fixture

PTFE tube inserted into peek isolator

Heat sink washer flush with peek isolator

PTFE washer flush with heat sink washer

5 heat sink washers and 4 PTFE washers installled

Complete heat sink

3 Assemble nozzle, threaded ext., heater block

Screw nozzle onto threaded extension, it just has to be finger tight

Take ~40mm piece of Teflon tape and wrap it around the threaded extension, flush with the nozzle, clockwise, while holding it vertical with the nozzle at the bottom

Screw heater block down over the Teflon tape and flush with the nozzle

Hold the heater block with your fingers and lightly tighten the nozzle with the 13mm wrench

Take another piece of ~40mm Teflon tape and wrap it clockwise around the top of the threaded extension

Threaded extension and nozzle

Teflon tape wrapped around threaded extension

Heater block installed flush with nozzle

Teflon tape wrapped around top of threaded extension

4 Assemble lower plate, backup plate, and peek isolator

Place the 2.0 lower plate(triangular wood piece) and 1.1 backup plate(triangular metal piece) onto the threaded extension

Screw the peek isolator onto the threaded extension till its flush with the threaded extension, making sure you don't pinch the lower plate in between the peek insolator and the heater block

Threaded extension w/ nozzle and heater block, 2.0 lower plate, 1.1 backup plate, and peek isolator

2.0 lower plate and 1.1 backup plate slide onto the threaded extension

Peek insolator threaded onto the extension

Orientation of the lower, and backup plate

5 Assemble heat sink, upper plate, mount plate

Insert the heat sink into the peek isolator, making sure the shorter side of the PTFE tube is inserted into the peek isolator

Slide the 2.0 upper plate over the PTFE tube

Now set the assembly into the counter bore of the mount plate

Line up all the bolt holes for the 3 M3x35 SHCS, making sure that the heater block is oriented correctly as shown

Insert alignment rod before you tighten the bolts

Tighten the 3 M3x35 SHCS with washers slowly, in an alternating pattern to insure evenness

Use the spacer to check the gap between the upper plate and the backup plate

Now insert the M3x4 set screw into the heater block

Use metal rod and check alignment, making sure it slides in and out smoothly

Mark bottom of lower plate with batch letter

Heat sink inserted into peek isolator

2.0 Upper plate placed onto PTFE tube, mount plate off to side

Assembly placed onto mount plate

Bolts and bolt holes lined up, note orientation of heater block

Bolts with washers installed, spacer

Alignment rod inserted before you tighten bolts

Use spacer to verify

Complete, note orientation of everything

Insert M3x4 set screw

Use rod to check alignment

Batch letter marked on bottom of lower plate

6 Resistor wire assembly

First strip two red 20 AWG wire on both ends about 5mm

Take the 4.7 Ohm resistor and slide a piece of the 20 AWG PTFE insulation over it then take a 16 AWG ferrule and slide it flush with the PTFE insulation, you might have to hold it in place with your finger

Slide the striped end of the red wire into the ferrule, the insulation of the wire should be flush with the ferrule

Crimp the ferrule with the wire crimper making sure that the wire or the resistor doesn't slide out

Pull the wire and resistor to make sure that they are secured within the ferrule and make sure the two are making contact within the ferrule

Slide a piece of the 11 AWG PTFE insulation over the ferrule making sure the insulation is centered over the ferrule

Crimp a male terminal connector to the other end of the red wire that is striped making sure that it is secure with proper contact

Repeat this on the opposite side of the resistor

Wire stripper

Wires stripped with hardware

Insulation over the resistor with ferrule and red wire fed into it

Ferrule crimped with 11 AWG insulation centered over ferrule

Stripped wire with male terminal connector

Crimped connector

Both sides done

7 Thermistor wire assembly

Stripe the orange 24 AWG wire the same as the red

Take the 100 Kilo Ohm axial thermistor and slide a piece of the 20 AWG PTFE insulation over it then take a 20-22 AWG ferrule and slide it flush with the PTFE insulation

Slide the striped end of the orange wire into the ferrule, the insulation of the wire should be flush with the ferrule

Crimp the ferrule with the wire crimper making sure that the wire or the resistor doesn't slide out

Pull the wire and thermistor to make sure that they are secured within the ferrule and make sure the two are making contact within the ferrule

Slide a piece of the 13 AWG PTFE insulation over the ferrule making sure the insulation is centered over the ferrule

Crimp a male terminal connector to the other end of the orange wire that is striped making sure that it is secure with proper contact

Repeat this on the other side of the thermistor, but make sure that you do not add another piece of 13 AWG PTFE insulation or attach another male terminal connector

Orange wire with hardware

Insulation over thermistor with ferrule and orange wire fed into it

Crimped ferrules with 13 AWG insulation on just one side

8 Wire the Budaschnozzle

Take the orange wire assembly and slide it through the small hole in the heater block, center the thermistor within the heater block, you may need to crimp the exposed ferrule extra for it to fit through the heater block

Do the same with the red wire assembly, centering the resistor

Now on the orange wire assembly you can slide the second piece of insulation over the ferrule and center it, and you can now crimp on the second male terminal connector

Route one side of the orange wire through the same side cutout in the lower plate, then do the same to the other side

Then with the mount plate oriented to the top of the assembly, route both orange wires through the left cutout in the upper plate, loop it around and down through the middle cutout and finally around and back up through the right cutout

Route the red wires the same way as the orange wires, except slightly twist the wires as you route them through the cutouts as shown

Insert the 4 male terminal connectors into the connector housing as shown, the clips on the male terminals should secure in the housing

Hold the 4 wires under the terminal housing to prevent putting strain on the pins and gently twist all the wires together as shown

Red and orange wires fed into heater block w/ thermistor and resistor centered