Bellows for the Makera Z1 (single material and no supports)

Keep chips off of your Z1's Y-axis linear rails with these printable bellows. No special multi-material printer required!

You will need to print one of each spacer type and two bellows for the front and back of the bed. You will also need a fresh razor blade, double sided tape, and a ruler/tape measure. (I used the tape that came with the Z1, but I presume some sort of 3M tape would be a lot stronger)


Notes on Successful Bellows Slicing/Printing:

• Make sure your TPU/PEBA is very dry - the bellows are 1 perimeter thick and any bubbles will show up as holes

• Double check your first layer heights - the bellows have a 0.2mm gap between baffles and an excessive elephant's foot will cause them to fuse

• Set Seam position to Aligned and place seam enforcers along the vertical point on the "{" shaped part of the model. Ensure that seams are only being generated there, and where shown in the image:

  

• Use a 0.4mm nozzle and 0.15mm layer height

• Set Perimeter generator to Arachne

• For those using Orca Slicer, ensure that Detect thin walls is checked

• Either print the front and rear bellows separately, or align them in such a way that travel moves do not cross over main body of the bellows

Post Processing the Bellows:

• The bellows are intentionally printed longer than then bed of the Z1 as when the printer turns a corner, the thin webs flex a little before returning to straight. The flexing causes some artificing which can be easily seen while using clear TPU:

  

• We are going to cut off the ends of the model to be left with perfect bellows

• Lay the model on its side so that the webs are parallel to your cutting board and then, using a FRESH razor blade, cut off the first end of the model. Remove about 2-4mm measuring from the base of the U shaped elements/where the step is. Cut by pressing straight down through the print. This will require a bit of force with a good blade, but will be nearly impossible with a slightly used blade

• If your first cut is not to your liking you can try again removing a 1-2mm slice, there is enough material on the other side to do this a couple times

  

• Cut off the other side such that you are left with a 204mm strip of bellows

Installing the Bellows:

1. Remove the spoil board from the bed

2. Thoroughly clean all mating surfaces with IPA

3. Apply double sided tape to both large sides of the spacers,leave the tape backing on, and use a blade to cut it so that it does not overlap the spacers.

4. Remove one side of the backing and attach the spacers to the back of the bed on either side of the tool setter wire. The spacers should be level with the top of the aluminum bed

5. Apply a 9mm wide & 204mm long strip of double sided tape to the front of the bed such that it is level with the top of the bed, and between the chamfers on the bed. Leave the tape backing on for now

6. Apply an 8mm wide strip of double sided tape to what will be the front bellows. Line it up with the bottom edge and leave the backing on

7. Apply an 11mm wide strip of double sided tape to what will be the rear bellows. Line it up with the bottom edge and leave the backing on

8. Remove the tape backing from the front of the bed. Carefully stick the un-taped side of the front bellows on such that the bottom of the bellows line up with the bottom of the bed and the bellows line up nicely between the chamfers on the bed

9. Remove the tape backing from the front bellows and slowly move the bed forward so that the bottom of the bellows can be aligned with the vertical lip of the Z1's housing. Once in place, slide a card or something similar between the folds of the bellows to press them firmly against Z1's housing. (Be careful not to pinch your fingers while moving the bed)

10. Remove the tape backings from the rear of the spacers. Carefully stick the un-taped side of the rear bellows on such that the bottom of the bellows line up with the bottom of the bed and the bellows line up nicely with the spacers

11. Remove the tape backing from the rear bellows and slowly move the bed backwards so that the bellows can be aligned with the rear wall of the Z1's housing. Once in place, slide a card or something similar between the folds of the bellows to press them firmly against Z1's housing. (Be careful not to pinch your fingers while moving the bed)

12. You're done!

Warnings

• The bed of the Z1 has a lot of holes in it that allow chips to fall onto the linear rails even with the bellows in place. I recommend plugging all unused screw/dowel holes or just covering them with masking tape to keep the rails extra clean

• The bellows collapse almost completely at the full range of the machine which could be problematic if they are filled with chips. Be sure to clean them before any CNC move that that might fully collapse the bellows

• If using a powerful vacuum to clean off the bellows be sure to keep it at an angle. I've made the mistake where the bellows suddenly get pulled to the vacuum nozzle and toss all the chips on them into the air