Introduction: Makerbot MK6+ Heater Replacement
this is a easy heater core that will get you up and operational from readily available materials for under $1US per core.
Step 1: Tools and Consumables
hookup wire
30-31gauge coated nicrome wire
kapton tape
soldder preferably high temp
1/4" OD copper tube
furnace cement
TOOLS
file
sciors
tooth pick
lighter
30-31gauge coated nicrome wire
kapton tape
soldder preferably high temp
1/4" OD copper tube
furnace cement
TOOLS
file
sciors
tooth pick
lighter
Step 2: Prep for Build
cut approximatively 1" of copper tube i use the edge of the file. !!!warning!!! if you crush the tube you will have to restart!!!
cut about 300MM of nicrome wire or 6 ohms worth so long as you are within 1 ohm it doesn't really matter but the closer the better
strip 1/4" of insulation off the nicrome ends
cut 2 lead wires about 12" and strip 3/8" off the ends
cut about 300MM of nicrome wire or 6 ohms worth so long as you are within 1 ohm it doesn't really matter but the closer the better
strip 1/4" of insulation off the nicrome ends
cut 2 lead wires about 12" and strip 3/8" off the ends
Step 3: Nicrome Time
fold the exposed nichrome in to a U shape than thread the lead around and through the U
wrap silver solder arround the twisted lead as shown below
melt the solder with a lighter not iron (too slow and fails more than half the time for me)
repeat fr the other side of the nichrome wire
once everything is soldered bend the leads opposite directions parallel to the wires as shown below
wrap each lead individually with kapton tape
wrap silver solder arround the twisted lead as shown below
melt the solder with a lighter not iron (too slow and fails more than half the time for me)
repeat fr the other side of the nichrome wire
once everything is soldered bend the leads opposite directions parallel to the wires as shown below
wrap each lead individually with kapton tape
Step 4: Packing the Nichrome
with kapton tape wrap the leads together as shown
fold the nichrome loosely into fourths
than fold it like a letter 3 times and this will be close to an inch long
fold the nichrome loosely into fourths
than fold it like a letter 3 times and this will be close to an inch long
Step 5: Insulating
squeeze some furnace cement out onto a paper plate of similar surface
the goal is to work the furnace cement in between all the nichrome wire
so work it in it doesn't matter what it looks like at this point so long as the wire is still in a bundle similar to what is shown below
the goal is to work the furnace cement in between all the nichrome wire
so work it in it doesn't matter what it looks like at this point so long as the wire is still in a bundle similar to what is shown below
Step 6: Packing the Core
take the bundle from the last step and add more cement to it gently press it inside the copper tube use the toothpick to fill any voids
cleanup the cement on the outside
let it dry for a day or 2 than proceed to the next step
or apply a low voltage current (1.5-3V) to it fr a few minutes at a time untill it stops steaming this makes a weaker core but will get you up and running faster
cleanup the cement on the outside
let it dry for a day or 2 than proceed to the next step
or apply a low voltage current (1.5-3V) to it fr a few minutes at a time untill it stops steaming this makes a weaker core but will get you up and running faster
Step 7: Installation
you NEED anti seize compound for this or it WILL get stuck in the core
coat the heater in anti seize than insert it as you would a regular MBI core and put the screw in with anti seize only finger tight
wrap the end with the leads coming out with kapton tape for reinforcement
insulate just as you would for a standard MK6+
coat the heater in anti seize than insert it as you would a regular MBI core and put the screw in with anti seize only finger tight
wrap the end with the leads coming out with kapton tape for reinforcement
insulate just as you would for a standard MK6+
Step 8: Results
after 20+ hours of printing the core is fine i think this is a rather robust design
the major con it that it takes 50 to 10 min to get up to temp depending on conditions in the room
the picture is my core after about 20 hours of printing there is a 608zz bearing for comparison
UPDATE (4/29/2012):
The original made in this instructable lasted about 50 hours of printing. a new version made with 4 ohms of nichrome wire it heats up the MK 6+ heater core in under 2 minutes and has been printing since September 2011with no maintenance. i have printed off 4 full sets of prusa mendel parts and lots of miscellaneous printing. which totals more than 100 hours.
the major con it that it takes 50 to 10 min to get up to temp depending on conditions in the room
the picture is my core after about 20 hours of printing there is a 608zz bearing for comparison
UPDATE (4/29/2012):
The original made in this instructable lasted about 50 hours of printing. a new version made with 4 ohms of nichrome wire it heats up the MK 6+ heater core in under 2 minutes and has been printing since September 2011with no maintenance. i have printed off 4 full sets of prusa mendel parts and lots of miscellaneous printing. which totals more than 100 hours.
