VORON 1.5: Building my DIY 3D Printer

The build begins & tapping aluminium extrusions

I ordered the wrong size self-tapping screws (M5 instead of M6), so I had to tap the aluminium extrusions manually.

I changed my BOM so nobody else has the problem.

Tapping threads into aluminium extrusion by hand

Self-tapping screws and aluminium extrusion pieces

VORON printed parts laid out on workbench

Close-up of tapped aluminium extrusion ends

Initial VORON parts and hardware spread on table

Tapping tool in an aluminium V-Slot extrusion

Installing frame & motors + first problem

Today I finally installed the frames and mounted the motors.

Also wanted to mount the A&B idlers but unfortunately the steel dowels have a diameter of 5mm and the inner diameter of the flanged bearings have an inner diameter of 4,96mm.

Already ordered new dowels with a diameter of 4mm. I updated the BOM accordingly.

V-Slot extrusions cut to length for the frame

V-Slot frame rails arranged before assembly

Frame extrusions with corner brackets attached

Assembled VORON rectangular frame structure

Frame with motors mounted to the corners

Stepper motor mounted on the VORON frame

Motor A and B mounted on the aluminium frame

Steel dowels and flanged bearings for idlers

Idler assembly with bearings on steel dowel

Frame assembly with motors and idlers in place

VORON frame viewed from above with installed components

Completed frame and motor assembly overview

Installing Motor Mounts

I installed the motor mounts. The parts for motor B fitted well, but motor A I have to print again (nut traps were too tight).

3D-printed motor mount installed on frame

Assembling the X carriage and mounting it to the Y rails

I assembled the X carriage and was absolutely amazed by this awesome design work. The nozzle probe works like a charm. Kudos russiancatfood!

While installing the “Chimera” hotend clone I found out that one of the heatbreak rods is stuck in the heatsink. I guess it will work, but I hope I can get the money back from the Chinese vendor.

X carriage assembled with belt path visible

Chimera hotend clone installed on the carriage

Chimera hotend heatsink with heatbreak rods

Close-up of the Chimera hotend heatbreak

X carriage wiring with connectors visible

Wiring harness and electronics on the VORON

Final assembly, first time pushing plastic

Worked yesterday 11 hours on my VORON and got it to push plastic :-)

The cable harness is still a mess, need some more time to clean up and calibrate.

I want to make the cables on my carriage unplugable, but my connectors didn’t arrive yet. So I used some “WAGO” clamps.

VORON printer fully assembled for first test

First extrusion test with filament coming out

Cable harness mess behind the VORON printer

WAGO clamps used for temporary wiring connections

VORON electronics board with WAGO wire connections

VORON printer running its first plastic extrusion

First layer being laid down on the print bed

VORON printer first print in progress at night

Dial indicator bed leveling

I created a dial indicator mount to level my bed more precisely. Works like a charm…

You can download the model from thingiverse: https://www.thingiverse.com/thing:2347217

3D-printed dial indicator mount on the X carriage

Dial indicator probing the print bed surface

Dial indicator reading during bed leveling

Bed leveling adjustment with dial indicator mounted

Dial indicator mount design on the hotend assembly

Finalized the build (or I thought so)

It took some time but I am finished with my VORON build. Just wanted to show the current state of build.

I am not quite happy with the cable management. I will probably buy myself a sheet of wood and put it on the backside of the VORON and attach to the sheet all the electrical stuff.

Let’s see what the future brings :-)

VORON printer front view with electronics visible

VORON printer side view showing cable management

Electronics controller board mounted on the back

Close-up of controller board wiring and connections

Rear view of electronics and power supply

Final result (still WIP)

I had some time to do my “final” adjustments to my VORON. The black boxes in the back annoyed me, so (as announced) I replaced it with a sheet of plywood and mounted there my controller stuff.

Additionally I replaced the part cooling fan duct by my own design, now I can use a silent 60mm SUNON axial fan. I published the custom fan duct on Thingiverse:

https://www.thingiverse.com/thing:2332578