Building the McWire RepStrap: A Homemade 3D Printer Journey
Building a 3D printer from threaded rod, lumber, and determinationโthe first step in the RepRap self-replication journey

From 2008 to 2012, I documented my experience building and refining RepRap 3D printers, starting with a crude wire-frame RepStrap and eventually achieving true self-replication with RepRap Mendel printers. This series chronicles the technical challenges, solutions, and evolution of early hobby 3D printing.
The journey demonstrates the RepRap philosophy: tools building better tools. The McWire RepStrap printed parts for a Mendel, which printed improved parts for a better Mendel, which enabled further innovations. Each machine made the next one possible.
These articles have been updated for clarity and readability in 2025, but preserve the technical reality of hobby 3D printing in 2008-2012. The challenges described, including unreliable electronics, inconsistent extrusion, and limited documentation, were typical of the era. Modern 3D printers benefit from over a decade of refinement building on this foundation.
The RepRap project’s vision of self-replicating machines democratizing manufacturing continues to influence open-source 3D printing today.
Building a 3D printer from threaded rod, lumber, and determinationโthe first step in the RepRap self-replication journey

Two years of extruder experimentation: from nichrome wire failures to reliable resistor-based hotends

Converting the McWire 3D printer into a CNC mill with a Dremel toolheadโthe beginning of workshop tool progression

Systematic troubleshooting solutions for extruder jams, flow issues, temperature problems, and mechanical alignment

Printing Mendel parts on the McWire and assembling a self-replicating printer capable of printing its own replacement components

A collaboration between electronics expertise and precision machining that created the J-Head, one of the most influential hot-end designs in RepRap history

Achieving the RepRap vision: the McWire printed a Mendel, which printed better Mendels, implementing true self-replication

Building a large-format dual-extruder printer with V-slot aluminum frame and multi-material capabilities
