Prusa Titan

My entry into 3D printing and additive manufacturing—a custom-built large-format printer based on modified Prusa i3 plans. Built from scratch with 8x the build volume of standard hobby printers, this project taught me electronics, motion systems, and the patience required for complex mechanical assemblies.

Primary Motivation: Print full-size stormtrooper helmets. Because why start small?

Build Volume: 18" x 18" x 26" (vs standard 8" x 8" x 8")

Research Phase (2014):

Explored RepRap community designs, evaluated different printer architectures (Cartesian, Delta, CoreXY), and identified key learning resources. The Prusa i3 architecture stood out for its:

• Proven reliability in community builds

• Straightforward assembly

• Well-documented design

• Available support from maker community

The Twist:

Found Instructables plans for "Mega Prusa i3" with 8x standard build area. Key advantage: minimal 3D-printed parts required (important when you don't own a printer yet).

Source: Mega Prusa i3 Rework on Instructables

Solution: Virginia Tech offered free 3D printing for students—problem solved.

Link to Printer: https://www.instructables.com/Mega-Prusa-i3-Rework-8-x-Build-Volume/

Phase 1: Research & Planning

• Initial budget target: $1,000

• Reality: $1,500 (more on this below)

• Created comprehensive Bill of Materials by:

  • Cross-referencing multiple designs

  • Sourcing parts from various suppliers

  • Optimizing for cost vs quality

  • Bulk ordering to reduce per-unit costs

Phase 2: Foundation Construction

Started with frame assembly using:

• Threaded rods and nuts (local hardware store)

• 3D-printed corner brackets (VT print services)

• Aluminum extrusions for rigidity

First Victory: Base assembly (~25 lbs) came together perfectly. Print bed moved smoothly on linear bearings. Seeing mechanical systems work as designed was incredibly satisfying—hooked on building from that moment.

1. Scale Complexity

• Larger printer = larger problems:

  • Heavier moving parts (inertia issues)

  • Longer unsupported spans (rigidity concerns)

  • Higher power requirements (electrical challenges)

  • More room for misalignment

2. First-Time Builder Mistakes

• Lack of bracing for the aluminum frame caused vibrations.

• Under-sizing holes

• Not creating a BoM in the beginning 

3. Budget Overruns

• $1,000 target → $1,500 actual

• Where the extra $500 went:

• "Better" components than BOM specified

• Modifications and upgrades

• Replacement parts from mistakes

• Tools not originally accounted for

Final Specifications:

• Build volume: 18" x 18" x 26"

• Heated bed: 18" x 18" (custom)

• NEMA 23 motors (higher torque for mass)

• Bowden extruder system

• RAMPS 1.4 controller

• Safety features: thermal runaway protection, fused power

Performance:

• Bad speed-to-print-quality ratio

• Gateway to understanding AM fundamentals

• Without a heated enclosure, large prints would warp

Technical Skills:

• Electronics assembly and wiring

• Motion system design and troubleshooting

• Firmware configuration (Marlin)

• Mechanical assembly and alignment

• Safety system implementation

Project Management:

• Budget estimation (and why it's important to overestimate)

• Parts sourcing and logistics

• Timeline planning

• When to follow plans vs innovate

Additive Manufacturing Fundamentals:

• Print parameter effects

• Material behavior

• Design for 3D printing

• Quality troubleshooting

Most Important:

Sometimes you need to build something just to understand it. This printer wasn't the most efficient path to owning a 3D printer, but it was the most valuable educational experience to what makes them run.