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Releases: gregsaun/prusa_i3_bear_upgrade

Bear Upgrade 2.1.1

08 Apr 07:45
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Improvements

  • Add PrintedSolid as new distributor
  • Add MK3S+ compatibility in documentation
  • Fix typo and sentences in documentation

Compatibility

This Bear Frame Upgrade 2.1 is compatible with the Full Bear Frame Upgrade 2.0 MK3 frame. If you do not know which frame you have please check our FAQ here. The 2.1 version needs extra hardware (screws, nuts, washers, dowel pin), check the bill of materials for more details. You can also order hardware upgrade kit from our distributor websites.

💡 If you have a Full Bear Frame Upgrade 2.0 MK2S or MK2.5 frame you can find compatible parts in the optional parts section below.

⚠️ The new Y and Z axis are not compatible with any of the existing Prusa or Bear 2.0 parts. You have to update all parts from Bear 2.1.

⚠️ The original Prusa firmware is compatible with the Bear Upgrade 2.1 only if you use the Original Prusa extruder and X axis. If you use the Bear upgrade 2.1 frame with BearExxa, BearMera or Bondtech extruders you will need to use custom firmware.

Download printed parts

Check the assets at the end of the release note.

Documentation

Special thank you

  • Thank you Jason from LDO Motors for the quality manufacturing and relationship.
  • Thank you to all my Patreon's for their precious support.
  • Thank you to Bendix Sørensen, David Ogles, Florian Däubler, Nathan Denkin, Orlando from All3DMakers, Sleene, Termlimit, Josh Jones and Stefan Maue for helping me with development, translation and support to the community.
  • Thank you to all official distributors for taking care of the kits and customers.
  • Thank you to everybody in the community for making it so good.
  • Thank you for making the community alive with all your comments, issues, pull requests, optional parts, make, pictures, etc.

Bear Upgrade 2.1.0

22 Aug 13:08
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Bear 2.1 Features

  • Compatible with Original Prusa i3 MK2(S), MK2.5(S) and MK3(S)
  • Reuse of as many parts as possible
  • Sturdy frame for faster printing
  • Improved accuracy
  • Reduced noise level
  • Easy to use and maintain
  • Built to last
  • High quality aluminum extrusions
  • Custom, sturdier t-nuts
  • Nicer, sturdier M5 screws
  • Precisely engineered printed parts
  • Thoroughly tested development
  • Highly customisable
  • Detailed documentation via guides.bear-lab.com
  • Active and open minded community
  • Truly open source

Improvements (since Bear 2.1.0-rc1)

  • New custom, sturdier t-nuts
  • Improved documentation
  • Better cable management for short cables
  • Larger feet to accommodate felt pads
  • New shape for build_helper_z to help during assembly
  • Increase tolerance of z_leadscrew_cap
  • Add STEP files
  • Simplify print settings
  • Convert Original Prusa SCAD files to STEP files
  • Automatic build of the release and asset files
  • Reorganization of the repository's structure

Bug fixes

  • [Full upgrade MK2s/2.5/3] Improve building guide #44
  • Suggestion for micro alignment of the Y axis rods #48
  • Manual improvements #49
  • Step 12.1 Could use a warning about Z motor cable lengths #53
  • add preflight check and disassembly as the first step in the assembly guide #64
  • ensure that all pulleys are tight #65
  • New 2.1 assembly manual #101
  • Rod length issue with ver 2.1 and mk2 optional build parts #106

Compatibility

This Bear Frame Upgrade 2.1 is compatible with the Full Bear Frame Upgrade 2.0 MK3 frame. If you do not know which frame you have please check our FAQ here.

💡 If you have a Full Bear Frame Upgrade 2.0 MK2S or MK2.5 frame you can find compatible parts in the optional parts section.

⚠️ The new Y and Z axis are not compatible with any of the existing Prusa or Bear 2.0 parts. You have to update all parts from Bear 2.1.

How to upgrade

From Bear 2.0

Reprint all parts and follow the assembly guide.

From Bear 2.1.0-rc1

It is not necessary to update your printed parts but if you really want to get latest improvements you can reprint those:

  • foot
  • z_leadscrew_cap
  • cable_clip_horizontal
  • cable_clip_vertical

Download printed parts

Check the assets at the end of the release note.

Documentation

Special thank you

  • Thank you Jason from LDO Motors for the quality manufacturing and relationship.
  • Thank you to all my Patreon's for their precious support.
  • Thank you to Bendix Sørensen, David Ogles, Florian Däubler, Nathan Denkin, Orlando from All3DMakers, Sleene, Termlimit, Josh Jones and Stefan Maue for helping me with development, translation and support to the community.
  • Thank you to all official distributors for taking care of the kits and customers.
  • Thank you to everybody in the community for making it so good.
  • Thank you for making the community alive with all your comments, issues, pull requests, optional parts, make, pictures, etc.

Bear Upgrade 2.1.0-rc2

19 Aug 08:17
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Release to prepare the final release of Bear 2.1, test the automatic release creation and have download links for the printed parts working.

Bear Upgrade 2.1.0-rc1

10 Jan 09:46
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What’s new?

New build helper

This release includes a new build helper for Y axis to help alignment of the left smooth rod with the frame. Build helper for Z axis has been redesigned to ease alignment.

Both build helpers have a special shape to avoid print artifacts like elephant foot, buldges, bad corners or uneven layers. This helps building your frame as square as possible even if your print isn’t perfect.

⚠️ Do not use the build helper for Y axis on both smooth rods. It is only designed to align left smooth rod and not to set the distance between the smooth rods.

New optional LCD cover

  • New accurate design from scratch
  • Makes the frame shorter thanks to a bevel in front
  • Eliminate vibrations
  • Easier to rotate LCD knob
  • Quicker to print and use less filament
  • Sleek design for better look
  • Optional: LCD supports compatible with stock Prusa MK3(S) frame
  • Available in several different look

Other improvements and fixes

  • Improve documentation on GitHub pages
  • Fix an issue where the shorter Bear frame 2.0 for MK2S, 2.5(S) was not able to reach the end stop on Y axis in some cases
  • Protection against elephant foot on some Y belt holders

Compatibility

This Bear Upgrade 2.1 is compatible with Full Bear Upgrade 2.0 MK3 frame. If you do not know which frame you have please check our FAQ here.

💡 If you have a Full Bear Upgrade 2.0 MK2S or MK2.5 frame you can find compatible parts here: optional_parts/bear_2.0_upgrade_mk2-2s-2.5-2.5s.

⚠️ The new Y and Z axis are not compatible with any of the existing Prusa or Bear 2.0 parts. You have to update all parts from Bear 2.1.

What should I re-print from 2.1.0-beta0 release?

Nothing needs to be reprinted except the Y belt holder for the shorter Bear 2.0 MK2(S)/MK2.5(S) frame.

What hardware is needed if I come from Bear 2.0?

Below the list is the hardware needed if you upgrade from Bear 2.0 to this new release. No changes are needed on the frame itself.

  • 1x M5x16 screw (button head ISO 7380)
  • 1x M3x30 screw (socket head ISO 4762)
  • 7x M3x25 screw (socket head ISO 4762)
  • 4x M3x18 screw (socket head ISO 4762)
  • 2x M3x14 screw (socket head ISO 4762)
  • 2x M3 square nut (DIN 562)
  • 2x M3 hex nuts DIN 934
  • 1x M3 hex nylock nut (DIN 985)
  • 1x M3 washer (DIN 125), 0.5mm thick
  • 1x Dowel pin, 2.95mm diameter, 15.8mm long (same as Bear X axis)
  • 12x M4x5mm set screw

Check temporary assembly guide to known where this hardware is used.

Thank you

  • Thank you Rebecca and Jason from LDO Motors for searching and building the best hardware for the final Bear 2.1 release. I know I can be very meticulous sometimes :D
  • Thank you to Josh Jones and Florian Daeubler for there development and tests on Bear 2.1 and future
  • Thank you to my Patreons for having tested the new LCD cover
  • Thank you to Tom Jackson for having tested the new LCD cover adaptation for orignal Prusa frame

Bear Upgrade 2.1.0-beta0

07 Nov 14:56
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What’s new?

New Z axis:

  • Overall stiffer structure.
  • Better holding of the Z smooth rod.
  • Avoid alignment issue due to 90° plates.
  • Easier to install and align.
  • Motor is a bit higher up.
  • Use M3x10 screws for motor.
  • Z motor mount use only two M5 screws.
  • Improve X axis ramming accuracy.
  • Reduce chances or warping during print.

New end caps:

  • Avoid end caps breaking by using smaller and longer set screw.
  • Nicer Z end caps.
  • No need to thread extrusions anymore.

New LCD supports

  • Shorter support to reduce printer length.

New cable clips

  • Use zip ties for horizontal and vertical clips.
  • Nicer look.
  • Stronger fit.

Compatibility

This Bear Upgrade 2.1 is compatible with Full Bear Upgrade 2.0 MK3 frame. If you do not know which frame you have please check our FAQ here.

💡 If you have a Full Bear Upgrade 2.0 MK2S or MK2.5 frame you can find compatible parts here: optional_parts/bear_2.0_upgrade_mk2-2s-2.5-2.5s.

⚠️ The new Y and Z axis are not compatible with any of the existing Prusa or Bear 2.0 parts. You have to update all parts from Bear 2.1.

What should I re-print?

Here are the parts you need to (re-)print from Bear 2.1.0-alpha1 release:

  • z_leadscrew_cap
  • z_motor_mounts
  • z_tops
  • lcd_support_a
  • lcd_support_b
  • y_end_caps
  • z_end_caps
  • cable_clip_horizontal
  • cable_clip_vertical
  • cable_clip_lcd

What hardware is needed if I come from Bear 2.0?

Below the list is the hardware needed if you upgrade from Bear 2.0 to this new release. No changes are needed on the frame itself.

  • 1x M5x16 screw (button head ISO 7380)
  • 1x M3x30 screw (socket head ISO 4762)
  • 7x M3x25 screw (socket head ISO 4762)
  • 4x M3x18 screw (socket head ISO 4762)
  • 2x M3x14 screw (socket head ISO 4762)
  • 2x M3 square nut (DIN 562)
  • 2x M3 hex nuts DIN 934
  • 1x M3 hex nylock nut (DIN 985)
  • 1x M3 washer (DIN 125), 0.5mm thick
  • 1x Dowel pin, 2.95mm diameter, 15.8mm long (same as Bear X axis)
  • 12x M4x5mm set screw

Check temporary assembly guide to known where this hardware is used.

Credits

Vecko Kojchevski Z axis parts: thingiverse.com/vekoj/designs . Vecko also gave me great feedback on the Z motor mount that were useful. Thanks!

Bear Upgrade 2.1.0-alpha1

15 Sep 11:30
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What’s new?

  • New PSU mounts for all Prusa’s PSU, including Prusa black Delta PSU.
  • New Rambo base mounts to make the Rambo cover stiffer. These new mounts are secured with 2x M3x14mm screws with 2x hex nuts (before 2xM3x12mm screws only).
  • New Y rod holders that increase the pressure made by the zip tie on the smooth rods. They are also more resistant to strong tightening.
  • Reduce Y idler tensioner adjustment range to 2.5mm (3mm before) to reduce risk of bad assembly and increase stiffness.
  • New optional parts for 9mm belt Y axis.
  • Improve documentation.

⚠️ This a work in progress, the current kits sold by our official distributors are not containing the hardware necessary for this upgrade. The Bear Upgrade 2.1 is going to have new features that will require other modifications.

Compatibility

💡 You do not need to upgrade the Bear frame if you come from Full Bear Upgrade 2.0 MK3 frame.

💡 You do not need to upgrade the Bear frame if you come from Full Bear Upgrade 2.0 MK2S or MK2.5 frame to use Bear 2.1 releases. However you will need a special belt holder available in the optional parts.

⚠️ The new Y axis is not compatible with any of the existing Prusa Y axis, you have to print all parts of this new Bear Y axis.

What should I re-print?

If you come from Bear 2.1.0-alpha0 or Bear 2.0 we recommend to replace all new parts that have been updated with this release and get the new hardware corresponding. It is a good time to cleanup and grease the Y bearings (or even replace them with new one). Here are the parts you need to re-print:

  • y_rod_holder
  • rambo_base_lower_mount
  • rambo_base_upper_mount
  • y_idler_mount
  • y_idler_tensioner
  • psu_lower_mount
  • psu_upper_mount

What hardware is needed if I come from Bear 2.0?

Below the list is the hardware needed if you upgrade from Bear 2.0 to this new release. No changes are needed on the frame itself.

  • 1x M5x16 screw (button head ISO 7380)
  • 1x M5x10 screw (button head ISO 7380 or Openbuilds low profile)
  • 1x M3x30 screw (socket head ISO 4762)
  • 7x M3x25 screw (socket head ISO 4762)
  • 4x M3x18 screw (socket head ISO 4762)
  • 2x M3x14 screw (socket head ISO 4762)
  • 2x M3 square nut (DIN 562)
  • 2x M3 hex nuts DIN 934
  • 1x M3 hex nylock nut (DIN 985)
  • 1x M3 washer (DIN 125), 0.5mm thick
  • 1x Dowel pin, 2.95mm diameter, 15.8mm long (same as Bear X axis)
  • 1x M5 T-Nut

Check temporary assembly guide to known where this hardware is used.

Bear Upgrade 2.1.0-alpha0

20 Aug 10:53
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What’s new?

Bear Upgrade 2.1 will have a single frame for all Prusa versions (MK2S, MK2.5(S) and MK3(S)). This single frame is exactly the same frame than Full Bear 2.0 MK3 frame.

The new release also introduces a complete new Y axis with the following features

  • New belt tensioner.
  • New stiffer Y motor mount.
  • New belt holder with clamping system.
  • Easier assembly of Y motor mount.
  • Creates a similar Y axis construction across all Bear frames.
  • T-nuts are placed were it is easy to swap them.
  • Compatible with E3D-Gates idlers.
  • Compatible with Bear Upgrade MK2S and MK2.5 frame (see optional part).
  • Helps to reduce Y axis stepper noise for MK3(S).
  • Increase homing accuracy of MK3(S).
  • Y bearing holders are now as standard (not an optional part any more).

⚠️ This a work in progress, the current kits sold by our official distributors are not containing the hardware necessary for this upgrade. The Bear Upgrade 2.1 is going to have new features that will require other modifications.

Compatibility

💡 You do not need to upgrade the Bear frame if you come from Full Bear Upgrade 2.0 MK2S or MK2.5 frame to use the new Y axis. It is compatible with Full Bear MK2S and MK2.5 frames thanks to a special belt holder available in the optional parts.

💡 You do not need to upgrade the Bear frame if you come from Full Bear Upgrade 2.0 MK3 frame.

⚠️ The new Y axis is not compatible with any of the existing Prusa Y axis, you have to print all parts of this new Bear Y axis.

What hardware is needed?

Below the list is the hardware needed if you upgrade from Bear 2.0 to this new release. No changes are needed on the frame itself.

  • 1x M5x16 screw (button head ISO 7380)
  • 1x M5x10 screw (button head ISO 7380 or Openbuilds low profile)
  • 1x M3x30 screw (socket head ISO 4762)
  • 7x M3x25 screw (socket head ISO 4762)
  • 4x M3x18 screw (socket head ISO 4762)
  • 1x M3 square nut (DIN 562)
  • 1x M3 hex nylock nut (DIN 985)
  • 1x M3 washer (DIN 125), 0.5mm thick
  • 1x Dowel pin, 2.95mm diameter, 15.8mm long (same as Bear X axis)
  • 1x M5 t-nuts

Check assembly guide of our manual to see where this hardware is used.

Bear Upgrade 2.0.0

23 Jul 14:02
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  • Stronger frame with extrusion on Z axis as well as XY.
  • Full and Half version of the frame.
  • Compatible with Prusa MK2S, MK2.5 and MK3.

Version 1.0

06 Dec 14:29
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  • First version of the Prusa i3 Bear Upgrade
  • Re-use original Z aluminum frame
  • Use Openbuilds aluminum extrusion in place of the threaded shaft