200mm 2020 Extrusion, modified for strength. Used in a DIY Rook 2020 MK2 Printer

Quite possibly the first 3d printed Rook, some people said it was stupid but even in it's early stages it's working very well.

This extrusion is modified to be as strong as possible whilst still keeping the same format as a standard 2020 extrusion.

A solid core maximises the strength whilst being easy to use, print and work with. I used these to make a cheap Rook 2020 MK2 from Rolohaun, Excellent printers, I suggest you check out his page :)

https://www.rolohaun3d.ca

The original design from Rolohaun has an open front, but due to the nature and limitations of the printed frame I decided to add an additional bar across the X as shown in the pics. If you follow the BOM of the original design, please take this into account (I've not tested this with an open front - milage may vary)

I printed these with JAYO standard PETG with the following settings. You can potentially use any material you like, I've been reliably told that PLA would be stiffer. I think they key to how strong these came out for me was the enclosure temp, even if filament does not need an enclosure, you can get great strength benefits because the layers melt together easier.

Print straight up
45c enclosure temp - this is close to getting problems with the extruder, use 35/40c to be safe.
Low Fan speed
0.6mm Nozzle
Outer/Inner wall 0.7
4 walls
240c nozzle temp

Be careful when torquing bolts + t-nuts, don't strip them :)

I've also added Experimental versions, please take a look and see if they would be more suitable for your use. I do have ideas to improve the printer/frame design further so please check back from time to time as I adjust and make improvements.

My aim is to bring ownership costs down to a minimum, in future I will be adding parts that will enable someone to take an old Ender 3 and use that Ender to print the parts and sacrifice itself to make a cost effective Rook.


Edits; 

Added corner reinforcement bracket (mirror in slicer as needed)

Added back panel, designed to increase stiffness and strength. 
 

I've not seen someone stupid enough to attempt a printed Rook before, so here it is. 

This is an ongoing project which aim's to being a great printer like to Rook to a wider audinance with significant cost reductions.

The original design calls for aluminium 2020 extrusions, I wanted to see if it'll work with printed extrusion, turns out it works very well for a fraction of the cost.