Update: FuseBox2R v1.1 files are available on Github. Reworked gantry is more rigid and has an improved belt path. A partially complete build guide has also been added.

FuseBox2/FuseBox2R

Github repo (Check here for latest part files, BOM, instructions, etc.): https://github.com/alexyu132/fusebox2

Update 7/27/18: STLs and files will now be on Github only.

Update 3/20/18: Modified extruder to be compatible with flexible filaments. Tested with TPU @25mm/s.

An affordable and robust CoreXY printer loosely based on the original FuseBox. Materials cost ranges from $300-400 largely depending on what hotend and electronics you choose to use.

FuseBox2R

Improves on the original FuseBox2 by replacing the gantry rods with a single MGN12 rail and MGN12C carriage. Improvements include 30% lower moving weight, quieter movement, easier access to carriage components and a modular cooling duct. With a clone rail, upgrading costs ~$15-20 and building from scratch adds about $5-10 to the total cost.

Videos

FuseBox2R v1.1 @ 250mm/s: https://youtu.be/t1YAJrRtNjg
170mm/s printing: https://youtu.be/dm6vGjRgSQ8
Marlin 2 speed test: https://www.youtube.com/watch?v=aUQ9sjp_YzY

Specifications and Features

• Rigid 2020(top and sides)/2040(bottom) aluminum extrusion frame
• Non-crossing CoreXY belt path
• 210x200x210mm build area
• 390x340x412mm size
• MK2 or MK3 PCB heatbed with 3 point leveling
• Strong part cooling blower (4020s)
• E3D V6 or Lite6 + 40mm cooling fan and Bowden extruder
• 24v + 32 bit electronics recommended

Improvements over original FuseBox

• Slightly more compact
• Slightly larger build area
• 2020 frame for much greater rigidity
• Belt tensioning improvements - much easier to tension and screw-clamped to prevent slipping out
• Screw-clamped bearing and rod mounts - no more structural zip ties
• Proper belt idlers - eliminates belt rubbing
• (Optional) Extrusions joined via tapped ends + screws instead of corner brackets
• Lowered part count - y rods integrated into motor and idler mounts
• Vertical gantry for easier hotend installation/removal and better cooling
• Better endstop mounting and easier adjustability
• Robust electronics mounting with integrated display and IEC switch/fuseholder mounts - PSU flipped upside down for a cleaner look and so cooling fan doesn't interfere with heatbed