Head plate

Download a zip file containing all the model files. The total amount of each part that should be made is in the BOM.

Here is the complete Bill of materials (, ) for this guide.

Tools and Materials

Tools:

• 3D Printer (x1)
• Bench grinder (x1), to bevel the locking leadscrew.
• M6 Tap (x1), to tap the flanges on the KFL08 bearing.
• M3 Tap (x1), to tap a hole for supporting the lock's main spring.
• Wire Cutters (x1), to cut the main spring and belts.
• Pliers (x1), to bend the main spring.
• Superglue (x1), to make loops in the ends of the locking GT2 belt.
• Square Crimper Tool (x1), to make a loop on the remote's cable.
  • Nice read on crimping ferrules: https://library.automationdirect.com/ferrule-ferrule-ferrule-right/

Materials:

• 2040 V-Slot Profile 400mm from the Z axis, part of the motion system.
• PLA Filament 1.75mm (x1)

Parts

Head-plate

Parts:

• KFL08 mount:
  • KFL08 Pillow Block Bearing (x1): Front support bearing. Must be M6-tapped on the flanges manually.
  • M6 x 8mm Screw (x2)
• Kinematic coupling:
  • Dowel Pin 4mm x 16mm (x6)
• Z-profile fixture:
  • M4 Drop-In Nut 2020 (x4)
  • M4 x 8mm Screw (x4)
• 3D-printed parts:
  • KFL08 headplate (x1) (source/HEADPLATE-KFL08.stl)
    • Check your bearing's dimensions before printing, as some KFL08 bearings are slightly larger.
    • Here is a bearing variant and a matching HEADPLATE-KFL08-V2-alt.stl

Locking mechanism

Parts:

• Custom parts:
  • Beveled 8mm OD x 36mm Leadscrew (x1): must be beveled manually on one end (THSL-8x4-SCREW-L36 reference model).
• Base part:
  • TC lock 608ZZ Bearing Base (x1) (source/608ZZ-BASE.V3.stl)
  • 608ZZ Bearing (x1): Back support bearing.
  • M4 x 6mm Set screw (x2)
  • M4 Hex Nut (x2)
• Cable guide:
  • TODO: add the PTFE segments and their 3D-printed holders
• Pulley:
  • TODO: add the updated pulley for new the steel cabble
  • TC lock shim (8x23x2mm) (x1) (source/AS-PULLEY-STOP-Compound.stl)
• Cable guide base for the Z-axis:
  • Cable guide Z base (x1) (source/CAR-Z-TC3-BASE.V1))
  • M3 x 25mm Screw (x2)

Spring loaded lock

Parts:

• 400mm OD 5mm ID Spring (x1) PLACEHOLDER
• M3 x 12mm Screw (x1), to fix the spring to the 2040 profile.
• Square Ferrule 1.5mm ID (x1)
  • TODO: this may not be necessary, test that it works with the new cable diameter

Tool plates

Each tool should design its plate based on this template:

• TOOLPLATE-WEDGE-V2.stl (source).

All tools share the same wedge-plate.

• THSL-WEDGE-PLATE-BEVEL-M3-COMP.stl
• This should be printed in detail (0.2 mm layer).
• Test the fit with a THSL Leadscrew OD8 L400mm leadscrew.
  • The leadscrew will smooth out imperfections in the print after a few passes.
  • It's ok if it requires some force at first and then softens.
  • However, reprint with XY-size compensation set to -0.1 mm if it's too tight.