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AO-101 60mm Print Height Increase

Posted: Sun Jun 02, 2013 2:40 pm
by Seesoe
this modification will increase the print height from 100mm to 160mm (3.9in to 6.29in). this was achieved with no additional hardware, just printing new parts. the ao-101 use 30 degree angled parts for the upper frame, i changed everything to 35 degrees to allow the carriage to travel higher.

parts and sketchup file can be found on thingiverse

you will need to reflash your firmware with the new Z_MAX_POS value to allow the printer to reach that height. you can find detailed instructions on how to do that here https://www.lulzbot.com/?q=support/re-f ... s-firmware

on about line 200 of Configuration.h change
#define Z_MAX_POS 100
to
#define Z_MAX_POS 160

and thats its, you'll now have over 6 inches of print height!

Re: AO-101 60mm Print Height Increase

Posted: Mon Jun 03, 2013 6:12 am
by jebba
Cool, thanks!

Re: AO-101 60mm Print Height Increase

Posted: Mon Jun 03, 2013 6:51 am
by Orias
This is pretty cool! Thanks for sharing this!

Re: AO-101 60mm Print Height Increase

Posted: Wed Jun 05, 2013 8:55 pm
by Gemini64
That's one must have upgrade! And it's so obvious I don't know how no one else (that I know of) thought of it! :D

Thanks for sharing this.

Say, I guess to make this upgrade you need to remove the whole top since the lowervertexmiddle part is fastened to the T-slot with a screw at the end. What I'd like to know is can you safely leave the X axis and vertical smooth and threaded rods there while making the change?

On the other hand I might do the Z axis revision (replacing the X end clamps) at the same time on my AO-100.

Re: AO-101 60mm Print Height Increase

Posted: Thu Jun 06, 2013 3:40 am
by lotw
Do you have a pic of what your printer looks like after this mod?

Re: AO-101 60mm Print Height Increase

Posted: Thu Jun 06, 2013 3:19 pm
by Seesoe
thank you all.

Gemini64, i was thinking the same thing, why no one thought of it before, or if someone did but ran into issues?

the process of converting all the parts over took some work. i pretty much did it in a frankenstein fashion by replacing the parts as i printed the next parts as i was making sure things worked out at the same time. at one point i was printing with nothing holding up the 4 x axis rods. :)

lotw, i'll get some pictures up in the next day or two

Re: AO-101 60mm Print Height Increase

Posted: Fri Jun 14, 2013 10:58 pm
by lotw
Any word of the photos?

Re: AO-101 60mm Print Height Increase

Posted: Fri Jun 14, 2013 11:38 pm
by Gemini64
While we wait for Seesoe to post pictures, here's a screen grab of his Sketchup model.
AO-101_print_height_increase_mod.png
Seesoe wrote:the ao-101 use 30 degree angled parts for the upper frame, i changed everything to 35 degrees
Actually it is 25 degrees rather than 35. ;)

Re: AO-101 60mm Print Height Increase

Posted: Mon Jul 08, 2013 7:37 am
by antfurn
Upgraded my AO-101 with this extra 60mm height mod over the weekend :twisted:
Haven't printed anything 'tall' yet. Standard prints seem to be coming out the same quality as before except that I seem to be getting more cooling layer separation issues.
I doubt it's this mod causing however, as I also swapped over to using the budaschnozzle v2.0 and I am now printing with a 0.35 nozzle instead of the 0.5mm nozzle.

I'll try post pics soon.

Antony

Re: AO-101 60mm Print Height Increase

Posted: Mon Jul 08, 2013 3:29 pm
by Gemini64
Nice, but you know what they say, pics or it didn't happen. :P

I was set to make this upgrade too, but I'm changing my mind. I still want the print height increase, but I'm thinking of going a little further and partially morphing my AO-100 into a small MendelMax 2.0. Just the aluminum frame configuration though, not the linear rails. Basically I want to open up the front because I find the front Z frame is in the way when I want to access the extruder. The MMax 2.0, Mendel90, Prusa i3 and to a lesser extent the TAZ are nice in the way their front is open.

But I'm going to start another topic about this.