OHAI: Open Hardware Assembly Instructions

1 Prepare Mini Toolkit – Several of these may be prepared for later use

Gather the following materials:

1x- 6 x 10” 6 MIL Re-closeable Bags (SH-PG0084)

1x- Pro Dental Pick w/ Sleeve (TL-HD0046)

1x- Clam Knife Sheath Sticker – Sharp! (DC-LB0062)

1x- Laser Etched Clam Knife – Sharp! (TL-HD0359)

1x- Tweezers (TL-HD0049)

1x- Brush (TL-MS0020)

1x- 2mm Allen Wrench (TL-HD0223)

1x- USB Drive, Pre-flashed w/ Logo (EL-MS0262)

1x- Wiper Pad set of 5 (AS-PR0023)

540mm of Wiper pad PP-FP0087 cut into 90mm lengths
1x- 3" x 4” 2 MIL Re-closeable Bag (SH-PG0002)

Instructions:

Insert the Brush (TL-MS0020) into the sleeve accompanying the Dental Pick (TL-HD0046).

Insert the Lulzbot Wiper Pads (5x 90mm lengths of PP-FP0087) into the 3x4” Bag (SH-PG0002) as pictured.

Apply the “Sharp!” Sticker (DC-LB0062) to the sheath of the Clam Knife (TL-HD0359)

Open the 6x10” Bag (SH-PG0084) and place all materials inside as pictured.

Mini Toolkit Materials Gathered

Mini Toolkit Prepared

2 Prepare Mini Document Bag - Several of these may be prepared for later use

Gather the following materials:

1x- 9x12” Recloseable Bag (SH-PG0083)

1x- Mini User Manual (DC-MN0014)

1x- Mini Quick Start Guide (DC-MS0032)

1x- LulzBot Logo Sticker, 3 - Inch (DC-LB0095)

3m- PolyLite PLA LulzBot Green Filament Sample (RM-PL0118)

Place LulzBot sticker (with backing still attached) inside the Manual between cover and first page

Open the 9x12” Bag (SH-PH0083) and place the items listed above inside the bag.

Order of bag content:

Manual is on the bottom (cover facing up),
PLA (RM-PL0118) is in the middle, and
Quick Start on the top with the cover facing up.

Mini Document Bag Materials Gathered

Placement of LulzBot sticker

Mini Document Bag Prepared, placement and order is critical

3 Prepare Mini Shipping Box – Several of these may be prepared for later use

Gather Materials Needed:

1x- Mini Shipping Box (SH-PG0076)

1725mm- White Reinforced Tape with LulzBot Logo (SH-PG0131) or 68"

Begin with the box upside down;

Fold the box bottom small end flaps into the box, then fold the long flaps over the end flaps;

Tape the bottom of the box with white reinforced tape- 28” long.

Apply a 20” strip across the bottom of the box at the box ends so the tape is centered on the box,

Fold down the two lengths of tape that overhang the face and rear of the box;

Fold down and adhere remaining flap of tape to the box. Repeat at the opposite end of the box

Box upside down

Bottom box flaps folded

Centering tape on bottom of box

Long strip applied

Box end tape applied, ends folded over

Folding tape corners

Fold remaining flap

Finished taped corners

4 Prepare for Packaging

Retrieve the following from the boxing queue:

Lulzbot Mini Printer, Calibrated

USB Cable (EL-CA0063)

North American Power Cable (EL-CA0030)

Completed Quality Assurance Record (DC-MS0029)

Octopus test print

Remove all items from Mini toolkit bag and add in the following order as pictured:

Power Cable (EL-CA0030)

USB Cable (EL-CA0063)

Lulzbot Wiper Pad set pf 5 (5x 90mm lengths of PP-FP0087)

Octopus Test Print

Tweezers (TL-HD0049)

Pick & Brush (TL-HD0046 & TL-MS0020)

USB Drive (EL-MS0262)

2mm Allen Key (TL-HD0223)

The toolkit when organized as pictured ensures that the octopus test print remains undamaged during the shipping process. Note the position of the octopus; upside down and on top of the wiper pad refills. The “Sharp!” sticker on the clam knife's sheath should also be facing up for additional customer safety. Once all items are in the bag and properly oriented, close the bag.

For UE/ UK shipments

Additional power cables EL-CA0031 (England/UK) and EL-CA0032 (EU) are added to the shipment

Place the England/ UK power cable (EL-CA0031) in the accessory bag in place of the North America power cable (EL-CA0030)

Place the North America power cable (EL-CA0030) and the EU power cable (EL-CA0032) into a 6”x 10” resealable bag (SH-PG0084) then seal the bag.

For Australian shipments

Additional power cable EL-CA0056 (Australian) is added to the shipment

Place the Australian power cable (EL-CA0056) in the accessory bag in place of the North America power cable (EL-CA0056)

Place the North America power cable (EL-CA0030) into a 6”x 10” resealable bag (SH-PG0084) then seal the bag.

Power Cable Inserted

USB Cable Inserted

Wiper Pads & Test Print Inserted

Clam Knife Inserted

Tweezers, Brush, and Dental Pick Inserted

Allen Key & USB Drive Inserted, Bag Closed

FOR EU/ UK- Accessory bag contents for EU/UK shipments, note the UK power cable is the only change

FOR EU/ UK- Packaged accessory bag shown, North America and EU power cords to be packaged

FOR EU/ UK- Completed power cable bag

FOR AU- Australian Power cord

FOR AU- Accessory bag contents for AU shipments, note AU power cable is the only change

FOR AU- Completed power cable bag, North America cable only

5 Prepare Documentation

Gather the following materials:

Mini Document Bag (pre-prepared)

EC Declaration of Conformity, Mini v1.0 (DC-MS0033)

Warning sheet, Mini (DC-MS0031)

Completed Quality Assurance Record (DC-MS0029)

Packing List, Mini 1.0 (DC-MS0028)

Complete the Packing list (DC-MS0028)

Copy the machine's serial number off of the Quality Assurance Record (DC-MS0029) and verify that both serial numbers match the serial number on the back of the machine
Fill out your name and today's date
Complete the checklist, ensuring that each item is present and complete

Verify printed documents are clean and free of any stains or damage.

Stack the documents in the following order:

1) Warning sheet, Mini (DC-MS0031)

2) EC Declaration of Conformity, Mini v1.0 (DC-MS0033)

3) Completed Quality Assurance Record (DC-MS0029)

4) Packing List, Mini 1.0 (DC-MS0028)

Flip the Packing List over, so that once the documents are in the bag, the Packing List will show on the back side of the bag.

If necessary, remove other items from the bag to ease insertion of the documents as it is important that they do not become creased or folded.

Place the other items back in the bag on the side facing the Warning Sheet, ensuring that the Quick Start Guide is on top, as pictured.

Mini Document Bag (pre-prepared)

Mini Documents (DC-MS0033, DC-MS0031, DC-MS0029, DC-MS0028)

Manuals removed from bag for document sheets to be installed, orientation important

Mini Document Bag Completed

6 Prepare Mini Printer for Packaging

Examine the machine:

Ensure customer facing surfaces are free of unacceptable cosmetic defects.
Ensure the Z-Axis has been placed in proper shipping position.
Ensure that the heat bed is free of unacceptable defects.
Verify the serial number sticker on the rear of the machine is present and matches both the Quality Assurance Record and the Packing List.

Gather the following materials:

3x- Small Smooth Rod Foam Block (SH-PG0149)

1x- Mini, Long Smooth Rod Foam Block 5" x 1 ¼" (SH-PG0150)

1x- Modification Warning Insert (DC-LB0063)

100mm- 1/2' Blue strapping tape (SH-PG0069)

Using two short lengths (~1”) of small blue strapping tape (SH-PG0069), affix the Modification Warning Insert (DC-LB0063) to the printer's heat bed, as pictured.

Place Three (3) small foam blocks (SH-PG0149) and One (1) large foam block (SH-PG0150) onto the foam length verification jig, verify each piece of foam at least meets the allowable minimum line and does not exceed the maximum allowable line.

Place one Small Foam Block (SH-PG0149) on the upper X-axis Smooth Rod, as pictured. Slide the extruder to the left and place the Long Foam Block (SH-PG0150) on the remaining length of the Upper X-Axis Smooth Rod, as shown.

Slide the Y-Axis towards you in order to apply one Small Foam Block (SH-PG0149) to the rear of the right Y-Axis Smooth Rod. Push the Y-Axis back in order to apply the last remaining Small Foam Block to the right Y-Axis Smooth Rod, as shown.

Modification Warning Insert on Heat Bed

Foam and verification length jig

Foam populated in the verification length jig

Minimum length line

Maximum length line

Small Foam Block placed on X-Axis

Extruder pushed left

Long Foam Block placed on X-Axis

First Small Foam Block placed on Y-Axis

Y-Axis pushed back

Last Small Foam Block placed on Y-Axis

7 Place unit into shipping container

Gather Materials Needed:

Mini Printer – prepared in previous steps

Mini Document Bag – Completed

Mini Toolkit Bag - Completed

Mini Shipping Box (SH-PG0076) – See above for preparation

1x- Mini Foam, Top and Bottom set (SH-PG0112)

1x- Mini Serial Number Sticker (DC-LB0029)

1x- Mini Small Foam Insert, 11 x 7 x 6, Grey Urethane Foam Pad (SH-PG0113)

1x- Mini Larger Foam Insert, 11 x 7 x 8, Grey Urethane Foam pad (SH-PG0114)

1725mm- White Reinforced Tape with LulzBot Logo (SH-PG0131) or 68"

1x- Filament Samples Bag Label – Mini (DC-LB0111)

1x- 9X12 RECLOSABLE BAG (SH-PG0083)

200mm- 2” wide blue poly tape (SH-PG0072) cut to approximately 100mm long

Orient the Shipping Box (SH-PG0076) on the stand upright, with the green outline for the serial number facing out. Locate the correct Serial Number Sticker (DC-LB0029) for the machine to be packaged, verify the serial number matches the number on the rear of the machine.

Apply the serial number sticker within the green outline. This should be on the same side of the box as the control box for the printer.

Locate the bottom packing foam (SH-PG0112), refer to picture for identification.

Place the Bottom Packing Foam (SH-PG0112) in the box, ensuring the flat side is facing up and the longer side is facing towards you, refer to picture for orientation.

Set the Small & Large Foam Inserts (SH-PG0113 & SH-PG0114) on a flat surface and orient so that they are both the same height. This orientation is the way the inserts must remain during the boxing process.

The Larger Foam Insert (SH-PG0114) will be placed in front of the machine, against the extruder.

The Small Foam Insert (SH-PG0113) will be placed at the back of the machine, as pictured.

Grab hold of the machine by using your fingers underneath each end of the Y-Axis and your thumbs holding the Foam Inserts in place, as pictured. The control box side of the machine should be facing you.

Lower the machine, along with the Foam Inserts into the box.

Apply force downwards on the top of the printer frame to ensure the printer is fully seated in the Bottom Foam Piece.

Ensure both Small & Large Foam Inserts and the machine are straight in the box, as pictured.

Locate the Top Foam Piece (SH-PG0112) and orient as pictured.

Place the Top Foam Piece on top of the printer and ensure that is fully seated.

Fold the top of the Mini Toolkit Bag over and place it in the area shown.

Place the Mini Document Bag over the Mini Toolkit Bag, with Start Guide "START HERE" facing up

Place available Filament Sample packs into the 9"x 12" resealable bag (SH-PG0083), label the bag with the sample filament bag label (DC-LB0111), seal the bag.

Place bagged sample filament into the box in the corner opposite the documents bag with the filament label facing up, secure the sample filament bag in and place in the location shown with 2x- 2” wide blue poly tape (SH-PG0072) cut to approximately 100mm long each.

Place [DC-LB0121] Save your Mini Packaging Sticker on the inside top flap of the box as pictured.

For EU/ UK shipments

Place the accessory bag in its location on top of the top foam, place the additional bag of power cables into the pocket next to an opposite the accessory bag

Install and secure the filament sample bag per normal procedure

Install the printer document package per normal procedure.

For Australian shipments

Place the accessory bag in its location on top of the top foam, place the additional bag of power cables into the pocket next to an opposite the accessory bag

Install and secure the filament sample bag per normal procedure

Install the printer document package per normal procedure.

Close and tape the box, utilizing the same procedure used to tape the bottom of the box. Ensure that tape is placed evenly and all edges pressed as flat as possible.

Shipping Box on stand showing green outline

Verify Matching Serial Numbers

Serial Number Sticker applied to box

Bottom Foam Identification & orientation

Top Foam Identification

Bottom Foam in Box

Shows orientation of Small and Large Foam Inserts

Shows how the Foam Inserts are placed on the machine.

Shows how to hold the printer and Foam Inserts while transporting

Shows machine w/ Foam Inserts being placed in box

Application of downward force

Printer fully seated in foam, Small & Large foam straight in box

Top Foam In Box

Mini Toolkit bag folded

Mini Toolkit Bag placed

Mini Document Bag placed with Start Guide facing up

Sample filament bag parts

Bagged and labeled Sample filament bag

Filament Sample Placed and secured

Additional Power cable bag added for EU/ UK as Australian Orders

Additional power cable bag for international shipments- Completed installation of all document and accessories

Accessory bag, Power cable bag, and Filament sample installed

"Save all Packaging" label

Save all Packaging label placement

Box closed and taped

8 Log Machine & Place on Pallet

Log the date, time, and your name, in the log entry containing the serial number that matches the Packaged Mini Printer. See your supervisor if you have questions regarding this step.

Once calibrated and packaged, the Lulzbot Mini 3D printer will then be stacked on heat treated pallets for shipping. Following this guide for pallet stacking will help ensure the printer arrives at its destination undamaged and will assist Shipping & Receiving staff in serial number tracking.

Retrieve a heat treated pallet from Shipping & Receiving. Heat treated pallets are identified by a stamp on the side that reads “HT” at the bottom. Refer to picture for example.

Lulzbot Mini printers are stacked 4 machines per layer, no more than 3 layers in height, for a total of 12 machines per pallet.

The machine’s serial number is located on a sticker on one side of the box. That side of the box should face the front or back of pallet, whichever is closest to the machine’s position on the pallet. Serial numbers are recorded both in the Boxing Log and on the “Serial Numbers By Pallet” sheet, which will be affixed to the completed pallet before being moved to Shipping & Receiving.

Place an empty heat treated pallet on the floor, with the pallet openings facing the Shipping and Receiving hallway.
Place the first packaged Mini printer on the pallet in position 1. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.
Place the second packaged Mini printer on the pallet in position 2. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.
Place the third packaged Mini printer on the pallet in position 2. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

5.Place the fourth packaged Mini printer on the pallet in position 2. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

This completes the first layer, proceed to second layer.

1.Place the fifth packaged Mini printer on the pallet in position 5. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

Place the sixth packaged Mini printer on the pallet in position 6. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.
Place the seventh packaged Mini printer on the pallet in position 7. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.
Place the eighth packaged Mini printer on the pallet in position 5. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

This completes the second layer, proceed to the third and final layer.

1.Place the ninth packaged Mini printer on the pallet in position 9. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

Place the tenth packaged Mini printer on the pallet in position 10. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.
Place the eleventh packaged Mini printer on the pallet in position 11. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.
Place the twelfth packaged Mini printer on the pallet in position 12. Make sure the side of the box containing the machine’s serial number faces the pallet openings, as shown. Record the machine’s serial number on the “Serial Numbers by Pallet” sheet.

This completes the third and final layer.

Before transferring the completed pallet to Shipping & Receiving, ensure that all Serial Numbers have been recorded on the serial numbers by pallet sheet.

Use a small piece of transparent tape to affix the “Serial Numbers by Pallet” sheet to the front of the pallet.

The pallet is now ready to be moved to Shipping & Receiving. Make sure to communicate with Shipping & Receiving Clerks for appropriate placement.

HT stamp on pallet