The type plate on the of the RepRap Industrial's rear side you find all information to precisely identify your 3D printer:

• Serial number
• Date of manufacturing
• Hardware Revision¹

¹ Starting with version 1.1.0 of the operating software RepRapOnRails you will also find the valid hardware revision in the [Setup] menu on the touchscreen.

• unintended usage of the RepRap Industrial
• false setup, commissioning, operation repair or maintenance
• operating the apparatus with defective, missing, improperly installed and/or malfunctioning equipment.
• unauthorized or inadmissible alteration of the electrical or mechanical equipment or the operating parameters of the apparatus.
• use of other than the specified replacement parts, tools, and/or operating materials
• exceeding the specified maintenance intervals
• cases of disaster and force majeure

The RepRap Industrial has been designed for stationary application. It is not equipped with special transport devices such as lifting eyes or handles. The feet provide sufficient clearance to lift the apparatus and carry it to the installation site.
While the RepRap Industrial is packed and on its transport palette, use a lifting cart or pallet stacker for transportation. Make sure that the weight is evenly distributed and secure the RepRap Industrial against tilting.

The RepRap Industrial is recyclable due to its low-pollution equipment. Nonetheless, the European Guideline 2002/96/EG (Waste Electrical and Electronic Equipment - WEEE) and the German Elektro- und Elektronikgesetz (ElektroG) forbid the disposal of the apparatus via the household garbage. For environmental friendly recycling and disposal of the RepRap Industrial please contact a certified electronic waste management professional.

• Use the RepRap Industrial for its intended use only.
• The RepRap Industrial must be in goor working order and in a safe state at any time. Check the apparatus prior to every commissioning and at regular intervals for wear, damage and cleanliness.
• Ensure that nobody can be injured by parts of the 3D printer.
• Fix any error condition or visible damage immediately. If prompt rectification is impossible, decommission the 3D printer and do not put it back to use unless all problems have been solved.
• Regard the local accident prevention regulation.
• Provide access to the operating manual for anybody operating the machine.

When the emergency stop is triggered, the microcontroller board responsible for the stepper motors, heaters and sensors is reset immediately and returns to idle state afterwards. Now it is safe to resolve any problems or defects in the build chamber.

The build chamber can then be reactivated via the [Print] menue.
Detailed information are provided in the Operating manual.

The following paragraphs name and explain all components of the RepRap Industrial to give you an exact overview. The terms are used consistently throughout this manual and will help you identifying any part you may wish to find or order as a spare part.

The RepRap Industrial is built on an alloy framework and is mainly divided into two chambers. The upper build chamber is covered with acrylic glass plates to provide insight during production. It contains all mechanical components. At the back cover, the filament supply is installed.

The lower electronic chamber is covered with opaque plastic plates and contains the electronic components and the mains adapter. All connections and the power switches are located here and the touchscreen for operation is mounted at the front cover.

All covers are fixed to the frame with M4x20 hexagon socket screws and hammerhead nuts, thus being easy to remove and making all around access possible to all parts if required.

All references concerning directions are defined throughout this manual as follows:

All movement directions of the axes are defined throughout this manual as follows:

All movements of the extruder drives are defined throughout this manual as follows:

The build chamber is the main production area with the vertically moving print table and the two-directional horizontally moving extruder head inside.
All electrical motors are installed at their working point and equipped with a water cooling system. The extruder head moves on an H-frame, tooth-belt-driven by two separate stepper motors in X- and Y-direction. The print table is lifted and lowered in Z-direction by a spindle drive.
For regulating the temperature inside the build chamber two heating resistors in separate housings heat the air which then is circulated through the chamber by the fans.
Cables and hoses are installed in and guided by cable carriers.
To minimize air pollution from dissolved substances, an additional fan circulates the air through a filter element filled with granules of activated carbon.
The access to the build chamber is the magnetically closed double door at the front.

The filament spools that provide the necessary material are installed at the rear of the build chamber next to the filament feed unit.

The extruder head is mounted to the traverse of the H-frame and moves horizontally in X- and Y-direction with useful operating ranges of X = 200 mm and Y = 185 mm.
It contains the filament drive gears forwarding the filament strands and the hot ends which melt and dose the material onto the print table. The filament is supplied through a hose from the filament supply and is clamped between the idler lever and the filament drive gear. The filament drive gear is rotated by the filament feed motor and thereby forwarding the filament strand.
Each hot end is provided with its own filament strand, thus enabling bicolored prints, printing two materials or two objects simultaneously or printing with different extrusion thicknesses (e.g. for outer contours and inner filling structures).
The left (primary) hot end is configured for standard single-extruder prints and is the reference nozzle for leveling the print bed. The right hot end is only leveled passively after the print bed has been aligned correctly with the primary hot end.

The hot ends are heated by heating resistors so that the filament is molten inside the nozzle.
To improve the thermal control of the melting process the nozzle seats are connected to the cooling system. The cooling ensures an even temperature distribution in a well defined area of the nozzles so that there is a preheating zone and a melting zone.

The nozzle is exchangeable to provide different bore diameters for different materials, layer thicknesses or print speed. Ex factory, the 0.35mm tip is preinstalled. Additionally, three nozzles with diameters of 0.25mm, 0.5mm and 0.75mm are included. The tips are distinguishable by the engraved markings.

The print table is mounted on the elevator assembly on a 3-point leveling support with set screws, so that the print bed can be height-adjusted for an even and accurate leveling. It is positioned accurate to the millimeter in Z-direction in its useful operating range of 280 mm by the spindle motor. Heating is provided by a flat heating resistor to provide optimal adhesion and even temperature distribution throughout the printing process.
To perform leveling, start the Print Bed Leveling wizard which will guide you through the process step by step. Additional information on leveling can be found in the Knowledgebase.
The print itself will be executed on the polyetherimide (PEI) print bed laid on the print table and fixed with bulldog clamps. In hardware revision 1.0.0 (find the valid hardware revision of your 3D printer on the type plate the 2.5 mm print bed is held down by two fixedly mounted downholders and two bulldog clamps.
With hardware revision 1.1.0 a new, thinner (1.8 mm) print bed is delivered. This could be realized due to the use of other fabrics and provides a more uniform temperature distribution at increased stiffness. The downholders have been replaced with two additional bulldog clamps to allow the use of print beds of different thicknesses.
The print bed can be exchanged for every print, thus minimizing interruption times during production.

Important print bed knowledge

The PEI glass fabric composite print beds are, in accordance with the RepRap Industrial's standards, optimized for printing ABS and are custom-made to Kühling&Kühling specifications. Due to the manufacturing process, they may show bends and curves which can make handling them a bit tricky. These flaws are accepted due to the superior properties of PEI compared to other subsurfaces when printing ABS. It also works fine with HIPS, PET-Copolyester, PVA and thermoplastic urethane (TPE-U). Other materials may require a different subsurface, be it another material or a special treatment with tape or glue.

PEI is highly resistant to a lot of solvents which makes it a suitable subsurface for a lot of materials since removing residues and refurbishing for the next print becomes quite easy.

Find more information about the custom-made Kühling&Kühling PEI print bed:

• Operating and handling are described in the Operating manual.
• Cleaning and care can be found in the Service guide.
• Read about materials and printing subsurfaces in the Knowledgebase.

Five electrical stepper motors, one per direction of the extruder head, one for lifting and lowering the print table and one per extruder head nozzle for forwarding the filament, provide all necessary movement for printing. All motors are equipped with water cooling to prevent overheating due to workload and the heating of the build chamber.

Sensors for positioning and temperature control are installed inside the build chamber.

Every axis is equipped with a Hall effect sensor and a magnet for accurate home positioning. If the Hall effect sensor nears the magnet and measures the defined threshold value of the magnetic field strength, the sensor effects a “stop” signal via the microcontroller. After all sensors have given this signal the moving axes are in home position. The home position is the reference value for all relative movement of the extruder head and the print bed.

Temperature sensors (thermistors) measure the relevant temperatures for the printing process, i.e. the extruder temperature, the print bed temperature and the build chamber temperature. All thermistors deliver their input signal to the microcontroller and thus effect switching on and off the according heating resistor.
The extrusion temperature is measured at the heating block near the heating resistor and the relevant values for the control of the latter.
The print bed temperature is measured directly at the heating pad with which it is looped in a control circuit.
The build chamber sensor is installed at the elevator assembly and measures the air temperature inside the build chamber. Its measurements influence the control of the heating resistors inside the heating elements.

A limit switch is installed at every filament inlet of the filament feed unit (see below).

The RepRap Industrial is designed for printing filament strands of a diameter of 2.85 mm with a tolerance of ±0.1 mm. More information about filament and materials can be found in the material section and the print preparation section of the Knowledgebase.
Two separate strands can be fed from the outside to the extruder head. One filament spool can be positioned on each spool carrier; a stop collar prevents them from falling down due to their rotation.
The end of the filament strand is manually inserted into the inlet of the feed unit and led through hoses to the two extruder nozzles. At the inlet the filament is put through a sponge that wipes dust off the strand to keep the material unsoiled before reaching the nozzle.
A limit switch registers the end of the filament strand when the spool is empty. The print process then is interrupted and the lack of material is signaled on the touchscreen. The printing process can be resumed after refilling the supply.

Since hardware revision 1.3.0 the RepRap Industrial 3D printer can be equipped ex factory with a wiper to enable high-quality dual extruder printing.

If ordered as an upgrade kit click here to find the installation instructions.

All control elements are installed in the electronic chamber together with the 12 V(DC) mains adapter and the cooling unit.

The chamber is completely covered with plastic sheets fastened to the aluminum frame with hexagon socket screws and hammerhead nuts.
The MOSFET power switching board consists of five MOSFETs that switch the four heating resistors of the build chamber heating and the heating resistor of the print table.

The RUMBA board (also reprap microcontroller board) controls all processes of the printing process, i.e. the drives, the heating resistors, heating fans and the temperature sensors. Exchangeable hardware components are the stepper motor drivers.

The BeagleBone Black embedded computer provides the GUI of the touchscreen and the ethernet connection and processes the G-codes of the slicing software.
Slots in the bottom cover provide an air inlet for the cooling unit.

The cooling unit consists of a pump with water reservoir, a radiator and the closed loop coolant circuit, which is filled with Innovatek Protect IP ready-to-use. The coolant is pumped in a circle past the motors and the extruder nozzles where it absorbs heat and is then cooled down by the radiator. The pump starts/stops automatically when the build chamber is switched on and off.
How to judge if refilling of coolant is necessary and the necessary steps are described in the Service guide.

At the rear cover you find the mains plug and the main switch of the mains adapter and the RJ45 ethernet plug for the network connection.

The cooling systems' accumulated warmth is dissipated via the radiator grill to the outside.
The type plate is positioned next to the fixing screws of the cooling water pump.

The wake button at the front panel provides a wake-up function and indicates the general operating status of the 3D printer. It is equipped with a light ring that is illuminated while operational and dims after the 3D printer has been shut down. Press the button to restart the 3D printer from standby.

Operating the RepRap Industrial is designed to be comfortable and intuitive. Therefore, a high-resolution 10“ TFT touchscreen mounted at the front panel provides an easy-to-use Graphical User Interface (GUI).

All operation of the RepRap Industrial is carried out via the RepRapOnRails operating software which provides status messages and control functions that can be chosen by simply tapping the respective buttons. Find detailed explanations of functions and operating procedures in the Operating manual.

In case you experience any trouble, please refer to the Service guide and Troubleshooting. If you cannot solve a problem with the information given there, you are always welcome to contact us personally. We are trying to improve these information constantly and will be grateful for your help when you encounter any previously undescribed faults or problems.

of the operating software is displayed on the right-hand side of Setup menu together with additional system information.

Set up the RepRap Industrial at a well aerated place with an all-season ambient temperature between 15 and 25°C and a relative humidity of 70%.
Position the RepRap Industrial on a flat, carrying and enduring surface with a load capacity of at least 75 kg.
To ensure unhindered aeration of the electronic chamber no soft, movable materials (e.g. table cloth, cardboard strips, paper etc.) may be placed underneath the apparatus to prevent clogging of the vent slots.
The required setup space must at least be 650 x 650mm and provide approximately 500mm free space to either side to enable unhindered access to the electronic chamber for service and maintenance work. At least 750mm free space must be left at the back of the RepRap Industrial to make changing the material easy and to ensure free air circulation at the ventilation grill in the back cover. At the front a free space of 1.250mm is recommended to allow easy operation with open chamber doors.
To easily access the touchscreen in a sitting or standing position the height of the setup table should not undercut 780mm.
A 230V power source must be within the range of the connection cable.

To unpack the machine, cut the tensioning straps of the wooden transport box, remove the lid and carefully lift the box over the printer.
Then cut the tensioning straps around the 3D printer and remove the wooden cover plate and the air cushion foil.
Set aside and store all parts of the transport packaging for later use, e.g. moving or shipping the 3D printer.

All moving components of the RepRap Industrial 3D printer are secured with blue tape against damage in transit.
Make sure all transport restraints named in the adjacent pictures have been removed before commissioning the 3D printer.

• Take the RepRap Industrial out of operation as described above.
• Drain the cooling system and collect the coolant. Dispose of the coolant according to your local guidelines and the manufacturer's data sheet.
• Disassemble all components according to their recyclablility and dispose of them adequately and lawfully.

The RepRap Industrial 3D printer features a low-maintenance design, thus regular maintenance is not required during normal operation. Regular cleaning will mostly suffice to keep your 3D printer running satisfactorily. In case of faults, refer to the troubleshooting guide and the Service Guide where most problems known to us and according remedies are lodged.