Overview:

After success of my firts PET Filament Machine I decided to build new one which will be more compact and neat.

Here you can see the new machine in operation:

Assembly Instructions:

You can find an instruction video with assemby here: Part 1, Part 2.

Bottom:

1. Print and cleanup all printable parts
2. Install rubber feet to the bottom case
   • 4x Rubber Foot
   • 4x M3 Nut
   • 4x M3x8mm Screw
3. Joint the left and right bottom case together
   • 2x M3 Nut
   • 2x M3x8mm Screw
   • 2x M3 Washer
4. Install power supply
   • 2x M3x6mm Screw
   • 2x Washer
5. Prepare main socket and power switch module
   • Length of the wires should be about 18cm
   • Two additional ground wires will be connected to the Al profiles
6. Install main socket and power switch module
   • 2x M3x10 Countersink Screw
   • 2x M3 Nut
   • 2x M3 Washer
7. Prepare wired for motor speed controller and thermostat
   • (+)/(-) wires … power supply → motor speed controller … 45cm, AWG18
   • (+)/(-) wires … power supply → terminal block … 35cm, AWG18
   • (+)/(-) wires … motor speed controller → motor … 55cm, AWG18
   • (+)/(-) wires … thermostat → terminal block … 14cm, AWG18
   • 2x (+) wires … thermostat → terminal block … 18cm, AWG18
8. Connect cables to power supply
9. Cover terminal block on power supply with terminal cover
10. Connect cables to motor speed controller
11. Mount the motor speed controller to the base body
12. Glue the terminal holder with terminal blocks (5-port, 5-port, 2-port) to the base body with double side tape
13. Connect +/- cables from power supply to terminal block
14. Exchange K type thermocouple by smaller version (3x15mm)
    • Modify the back of thermostat case to connect thermocouple wires without tension
15. Connect cables to thermostat
16. Push the thermostat to the base body
17. Connect cables from thermostat to the terminal block
18. Install 40mm side panel fan and connect it to the terminal block
    • 4x M3x30mm Countersink Screw
    • 4x M3 Nut
    • 4x M3 Washer
19. Connect cartridge heater to the terminal block
20. Organize all cables
21. Cut threads into the Al profiles from side (if you want to mound side feet and handle)
22. Clear the paint/anodized surface to have good contact for ground wires
23. Mount the Al profiles into the body
    • 10x M5x12mm Screw
    • 10x M5 Nut + TNut_3030_M5
24. Connect ground wires to the Al profiles
    • 2x M5x10mm Screw
    • 2x M5 Nut + TNut_3030_M5
    • 2x M5 Big Washer
25. Mound side holders
    • 2x M5x12mm Screw
    • 2x M5 Nut + TNut_3030_M5
    • 2x M3x10mm Countersink Screw
    • 2x M3 Nut

Top:

1. Screw big gear and spool side to the spool cylinder
   • 16x 3.5x20mm Screw
2. Install Cover Plate 1
   • 2x M5x12mm Screw
   • 2x M5 Nut + TNut_3030_M5
3. Push the bearings into Motor and Bearing Plates
   • 2x Bearing 608ZZ
4. Mount Motor and Bearing Plate (don't tight the screws)
   • 5x M5x12mm Screw
   • 5x M5 Nut + TNut_3030_M5
5. Mount motor
   • 4x M3x10mm Countersink Screw
6. Mount motor lock mechanism
   • 1x M3x15mm Screw
   • 1x M3 Nylon Lock Nut
   • 1x M3 Washer
7. Mount small gear to the motor
   • 1x M3x10mm set screw
   • 1x M3 Nylon Lock Nut
8. Install the spool
   • 1x 125mm M8 threaded rod
   • 2xM8 Nut
9. Glue together two parts of the fan mount
10. Screw the 4020 fan to the fan mount
    • 3x Nut M3
    • 3x Screw M3x25mm 
    • 3x Washer M3
11. Install the fan mount to the body and connect the fan to the terminal block
    • 2x M5x12mm Screw
    • 2x M5 Nut + TNut_3030_M5
12. Assemble heater block holder and install heater block
    • 1x V6 Nozzle drilled 1.7mm
    • 1x V6 Heater block
    • 1x L-shape holder 30x30mm
    • 1x Al plate 110x30 mm
    • 6x M5x12mm Screw
    • 4x M5 Nut + TNut_3030_M5
    • 2x M5 Nylon Lock Nut
    • 2x M5 Washer
13. Install cartridge heater and thermocouple into the heater block
14. Assemble and install strip holder
    • 2x M5x12mm Screw
    • 2x M5 Nut + TNut_3030_M5
15. Install Cover Plate 2
    • 2x M5x12mm Screw
    • 2x M5 Nut + TNut_3030_M5
16. Connect motor to the speed controller
    In my case the polarity is opposite than indicated on the motor to have correct rotation direction. In case the direction is not as you want switch the polarity.
17. Mount motor cover
    • 4x M3x6mm Screw
18. Mount handle and feet 
    • 4x M8x20mm Screw
19. Add steal cord
    • 1x Approximately 40 cm steel cord 1mm in diameter
    • 1x Screw terminal
    • 1x Clip for steel cord (can be substituted with screw terminal)
20. Wrap wires to motor and heater block (optional)
    • 2x Approximately 20cm of woven wire wrap 5mm diameter

Electronics:

Here is the schematic of the electronics:

Bill of Material:

• Base 
  • 1x Bottom_Case_Right_EdgeCircles.stl (115g)
  • 1x Bottom_Case_Left_EdgeCircles.stl (93g)
  • 1x Side_Holder.stl (6g)
  • 2x Foot.stl (2x6g)
  • 1x Handle.stl (25g)
  • 4x rubber foot
  • 14x M3 Nut
  • 10x M3 Washer
  • 6x M3x8mm Screw
  • 4x M3x10 Countersink Screw
  • 4x M3x30mm Screw
  • 2m AWG18 red wire red
  • 2m AWG18 black wire black
  • 20cm of brown, blue, yelow/green wire 
  • 2x ground connection 
  • 12x M5x12 Screw
  • 2x M5x10 Screw
  • 14x M5 Nut
  • 4x M8x20mm Screw
  • 2x M5 Big Washer
  • 14x TNut_3030_M5.stl
     
• Spooler
  • Body
    • 1x Motor_Plate.stl (25g)
    • 1x Bearing_Plate.stl (40g)
    • 1x Distance_Ring_1.stl (<1g)
    • 1x Distance_Ring_2.stl (<1g)
    • 2x Washer.stl (<1g)
    • 5x M5x12mm Screw
    • 5x M5 Nut
    • 5x TNut_3030_M5.stl
  • Motor
    • 1x Gear_17_Teeth.stl (8g)
    • 1x Set screw M3x10mm
    • 2x Nylon Lock Nut M3
    • 1x Motor_Mount_Front.stl (6g)
    • 1x Motor_Mount_Back.stl (6g)
    • 4x Screw M3x10mm (flat head)
    • 1x Motor_Mount_Lock_1.stl (<1g)
    • 1x Motor_Mount_Lock_2.stl (<1g)
    • 1x Motor_Cover.stl (28g)
    • 1x M3x15mm Screw
    • 4x M3x6mm Screw
    • 1x M3 Washer
  • Spool
    • 1x Gear_55_Teeth.stl (44g)
    • 1x Spool_Cylinder.stl (105g)
    • 1x Spool_Side.stl (20g)
    • 16x Screw 3.5x20mm
       
• Cooler
  • 1x Fan_Mount.stl (28g)
  • 3x Nut M3
  • 3x Screw M3x25mm 
  • 3x Washer M3
  • 2x M5x12mm Screw
  • 2x M5 Nut
  • 2x TNut_3030_M5.stl
     
• Heater Block
  • 1x L-shape Holder 30x30mm (i.e. L-shape Holder)
  • 1x Al plate 110x30 mm based on Heater_Block_Holder_Template.stl
  • 1x Heater_Block_Holder_Distance_1.stl
  • 2x Heater_Block_Holder_Distance_2.stl
  • 6x M5x12mm Screw
  • 4x M5 Nut
  • 2x M5 Nylon Lock Nut
  • 2x M5 Washer
  • 4x TNut_3030_M5.stl
     
• Strip Holder
  • 1x Strip_Holder.stl (28g)
  • 1x Strip_Holder_Washer_1.stl (12g)
  • 1x Strip_Holder_Washer_2.stl (10g)
  • 1x Strip_Holder_Nut.stl (3g)
  • 2x M5x12mm Screw
  • 2x M5 Nut
  • 2x TNut_3030_M5.stl
     
• Covers
  • 1x Cover_Plate_1.stl (40g)
  • 1x Cover_Plate_2.stl (12g)
  • 3x M5x12mm Screw
  • 3x M5 Nut
  • 3x TNut_3030_M5.stl
     
• Electronics
  • 1x Power Socket with Switch (i.e Power Socket with Switch AC-01A) 
  • 1x 50W Cartridge Heater (i.e Cartridge Heater)  
• Other
  • 1x Power_Connector_Cover.stl (6g)
  • 1x Terminal_Cover.stl (6g)
  • 1x Terminal_Holder.stl (3g)

About 680g of filament is needed in total.

The total cost is about 100 USD.

Accessories:
For cutting the PET strips from bottles you can use my Simple PET Bottle Cutter.
For storing PET strips you can use my PET Strip Spooler And Spool Holder.