3D Printer

AllHandsActive has two Makerbot Industries Cupcake series 3D Printers. The printers are both heavily modified from their original state so aside from the chasis saying Cupcake, refer to documentation shown below.

3D Printer workstation

About

A small netbook (host name: FLICKY) sits with the 3D printers. Use the 'AHA' login with the usual back room password. ReplicatorG is installed (on desktop) and setup for use with Creamcheese. It has an SD card slot so you can also use it to build to card and print from that. Feel free to use the netbook and take it along when you transport printers. Unplug and shut down when not using it. No need to burn out the power supply/battery.

Known issues

Replicatorg loads full screen, right click on program in XFCE top bar and say always on top, this will then put the window in the right place and allow you to resize. Alternatively attach a larger monitor.

Maintenance and upgrades

Machine is maintained by: Tyler W.

• This machine does not have the latest Config files for the bots (7/2/12)

Creamcheese Cupcake

This bots history

This machine started as a Cupcake with Gen3 electronics and Gen3 Extruder. The extruder never worked right and became a hacked version of the DC extruder and a makergear hot end. The X and Y axis were changed to be quieter and more accurate. The DC extruder died during a 3D printing talk at Penguicon 2012. We discovered that we cannot easily source many of the parts we originally used and decided to build something that we could repair in the future. We decided on a Stepper extruder with 3MM filament feed as we had many pounds of it sitting around.

We use the Sailfish firmware with Rob G's 5D cable hack (similar to just using the 5D shield). Recently we added 3 pololu stepper drivers on the A, X and Y axis allowing us to push the machine a bit faster.

Because of the machines build we require that you use slic3r for slicing a STL file. Then use a special version of Replicatorg to run the produced Gcode file either from SD card or via cable.

Things this bot has:

• Gen3 Electronics (V2.x Steppers x 3, Motherboard RepRap v1.2, Extruder controller 2.2)
• NEMA 17 Cork Gaskets - Cuts down on noise
• Extra Stepper driver for extruder (Makerbot V2.x)
• Ugly cable hack does this, looks like [1]
• Sailfish firmware
• MiseryPusher Extruder
• Custom designed toolhead holder
• Mendel X and Y low rider Axis
• Relay mount kit
• Relay board kit
• MB Heated Build Platform
• Makergear Groovemount insulator
• Modular thermistor
• Modular heater core
• 36MM Brass barrel
• .35MM nozzle.
• Kysan 13.6:1 Stepper Motor (the same that Makergear.com sells)
• 3x Pololu 1/16th step stepper drivers
• PSMD board for new stepper drivers

What do I need to run Creamcheese? (UPDATED 10/4!)

• Get ReplicatorG 0039 Sailfish edition (MUST BE THIS VERSION!) - Sailfish Replicatorg/
• Get Slic3r 0.9.3
• Get the Creamcheese config files from here: Tyler's repository of cool stuff! - UPDATED 8/* (THESE ARE NOT YET PUBLISHED AS OF 10/4 AM!)
• Put the *.xml files in your replicatorg machines directory
• Load the config.ini file into slic3r.

Printing with Slic3r and Replicatorg

• Get a model in STL format ([Thingiverse.com] or cad program)
• Start Slic3r and make sure Creamcheese settings are loaded
• Under Print Settings, change fill density and shells. We recommend .30 fill density and 2-3 shells.
• Under platter drag your STL files into slic3r or use the Add button. Move things so they will fit.
• Press export GCode.
• Open ReplicatorG and connect to CreamCheese with machine type CreamCheese - Slic3r (supported)
• File->Open and pick your newly generated GCode file
• Pick build to file
• Save the resulting .s3g to an SD card with a filename no longer than 7 character.
• Put the SD card in the bot
• In ReplicatorG open tools->control panel.
• Preheat the bot to 220 and the platform to 110. When it reaches temp turn on the extruder until plastic comes out.
• Clear nozzle and lower to center of platform only a very tiny bit above it. You can use the controls in the control panel to do this or manually move it.
• Close control panel and pick build from file.
• Choose your .s3g file from the list.
• If print doesn't stick at start, hit cancel, clean platform and try again.
• After finish let print cool on platform. When cool the print should remove easily without deforming.

FAQ

• What happened to Skeinforge/Why do I need Slic3r? It was much easier to get good prints from Slic3r and generating Gcode is faster. ReplicatorG doesn't have great documentation but we provide files you can use to set it up for non-accelerated prints. In theory all you need to do is change the feed rates to something higher with acceleration but it didn't produce good prints.
• Why can I no longer print over the USB cable/Why should I use the SD Card? We added the 1/16th step drivers and it creates a lot of traffic that the USB cable link can't handle for parts with lots of little tight corners. You can still print over USB for smaller objects if you want. Try it! If your print pauses and has blobs use the SD Card instead. Another advantage is if your computer dies or sleeps the printer will keep working via SD Card.
• But a USB cable is super fast! What gives? The USB cable looks like a USB cable, but it is really a USB to Serial cable. The makerbot talks to the computer over serial and that is significantly slower than the USB maximum.
• My print didn't work. It said it printed but it did nothing. What did I do wrong? Make sure you used a short file name when making the S3G file. Long file names cause the bot to do this.

Making your own configuration files

3D_Printer:Creamcheese:Config <---How we configured it

Contact

Questions? Can you borrow it? Break something? Contact one of the following people!

• Tyler W.
• Nate Y.
• Josh W.

BlackBottom Cupcake

This bots history

This machine started as a Cupcake with Gen3 electronics and Gen5 Extruder. The DC extruder was upgraded by Ox to a Gen5/6+ stepstruder. The bot originally was given a 3G5D board but it never worked well. As a result we did the ugly cable hack.

At some point Ox decided to donate this bot to AHA!

It was renamed from Ox's bot to BlackBottom Cupcake (alternate name for a creamcheese cupcake) on 7/1/12

Things this bot has:

• Gen3 Electronics + Gen4 stepper for extruder
• Mk6 Stepstruder
• Acrylic Platform
• .40MM Nozzle
• RobG's 3G5D firmware.

How Do I run BlackBottom Cupcake?

Printer currently broken: Firmware needs to be updated to Sailfish and documentation updated. If you need to 3D print something in the meanwhile, you should use Creamcheese.

Once you have the bot configured, but before printing.... move the nozzle up and run the extruder manually from ReplicatorG to ensure it is feeding properly. This only needs to be done for the first print or after changing colors.

• Get ReplicatorG 0029 R2 (MUST BE THIS VERSION NOT NEWER!) - Google Code Listing
• Get the Creamcheese config files from here: Tyler's repository of cool stuff! - UPDATED 7/2
• Put the *.xml files in your replicatorg machines directory
• Put the folders (ex. SF40-BlackBottom-Cupcake-3mm-.35SD) folders in your sf_40_profiles folder.
  • On linux this is in a hidden home folder directory (ex: /home/worman/.replicatorg/sf_40_profiles
  • On Windows this is approximately: "\replicatorg-0029_r2\skein_engines\skeinforge-40\skeinforge_application\prefs\"
• Start up replicatorg and pick machine type of BlackBottom Cupcake 3G5D (RPM)
• In Replicatorg: GCode->GCode Generator pick Skeinforge 40 (Experimental)
• Use the following settings when you generate GCode...
  • Base Profile: SF40-BlackBottom-Cupcake-3mm-.40SD (if you put the config in the right place this will show up). The SD version is setup to print from an SD card.
  • Raft: Your choice, on or off.
  • Support Material: Your choice, on or off
  • Use Print-O-Matic: YES!
  • POM-Settings-Object Infill: 15% (Less and you get a hollower object, more and it is more solid.)
  • POM-Settings-Layer Height (mm): 0.30 (Smaller and bot moves faster stretching the plastic, larger and it will tell you can it can't print thick layers because of nozzle size)
  • POM-Settings-Number of shells: 2 (How many solid outer layers you get)
  • POM-Settings-Feedrate (mm/s): Variable. 35 is a good slow number.
  • POM-Plastic-Material type: ABS
  • POM-Plastic-Filament Diameter (mm): 2.94 (This should be an average thickness of the filament you feed in. It does vary by color and over lengths of filament. You might want to play with this when changing colors. Measure every 6 inches to a foot and average..)
  • POM-Extruder-Nozzle Diameter(mm) - .40 (DIFFERENT FROM CREAMCHEESE)
  • POM-Extruder-Drive Gear Diameter(mm) - 10.58
• Click build to file
• Save .s3g file to an SD card (or usb stick and then transfer to SD on the mini computer.) Be sure to use 16 CHARACTERS OR LESS in the file name!!!!
• Put SD card in bot (while it's off or on, doesn't seem to matter).
• In replicatorG tell it to build from file and pick the file from the list.
• Watch it go...

Contact

Questions? Can you borrow it? Break something? Contact one of the following people!

• Tyler W.
• Josh W.
• Michael Sh.

Comments

• 09/16/2012 ~1800 - ALIVE:
  • Printing the CuteOcto file on the card works fine.

• 09/16/2012 ~1720 - ALIVE:
  • Same as before, but this time using the CreamCheese Cupcake slicer (supported) machine type
  • Rebuilt gcode -> s3g file after closing Replicator 0029, copying creamcheese xml file over machines directory, selected CreamCheese Cupcake slicer (supported)
  • Transported file from local system to SD Card, build from SD Card
  • Print head immediately goes over the front left corner of build platform.

• 09/16/2012 ~1845 - ALIVE:
  • ReplicatorG 0029 Jetty downloaded from the link above
  • Using slic3r downloaded from above
  • Loaded slicer.ini file w/printer/filament/print files emailed from Tyler
  • Adjusted fill density to 0.35
  • Loaded 10mm Cube from reprap test site into slic3r
  • Exported GCODE
  • Replaced all capital Es with Capital As (1386 adjustments made)
  • Opened GCODE in replicator0029
  • Built to file 10mmc.s3g
  • Loaded file onto SD Card
  • Brought CreamCheese up to 220/110.
  • Attempt to test extrude
    • Motorspeed 30 (RPM)
    • Extrude Duration 1s
    • Hitting Reverse causes it to feed out for ~10 seconds
  • Test extrude works
  • Print head is centered on platform for x/y/z.
  • Selecting build from SD Card
    • FAIL: Print head immediately heads towards front left corner of build platform. This has happened twice in a row, each step above going through in the same fashion. If I don't hit stop quickly enough, the platform will continue moving until it runs out of room.

• 08/04/2012 ~1230 - ALIVE: Something (not a motor) is making a buzzing noise, usually for <1 second, seems to do it more when the extruder is close to ~220 temp. Maybe the relay? The noise happens both when you are printing, and when you are waiting for printer to come to temp.

• 08/04/2012 ~1530 - DEAD: Angry Black Bottom! One successful 10mm cube print on Black Bottom prior to class.
  • Created a 20mmCubePrint, generated GCode, loaded onto SD Card
  • Went to print, plastic didn't seem to be adhering to platform
  • Lowered head down a bit, it looked to be a bit too high
  • Extruder head caught on platform as a result of it being too low.
  • Attempted to stop in ReplicatorG, hitting stop button did not change anything
  • Turned BlackBottom off via the Motherboard Switch, this stopped it.
  • Waited a few minutes, repositioned head, turned Motherboard switch back on, and we get:
    • Three Red Flashes, Pause, Red Flash, Long Pause, Power LED on Motherboard, and green LEDs on other boards light up for a brief second, then all lights are off EXCEPT for a very dim green light on the stepper controller for the extruder.
  • Power down, disconnect, reconnect, reset, etc. do not appear to help at all.

• 08/04/2012 ~1640 - ALIVE: After multiple resets, power downs, complete disconnects from power. I turned it on while pulling on the modified wire mashup connected to the RepRap Motherboard (that go down to the Extruder Stepper Controller)
  • Wires possibly coming loose from the connection to the pins / shorting out?

The Replicator

This Bots History

This bot was won by Backyard Brains and is for their use only.

How do I run the Replicator?

You probably should not (unless you are BYB!). Slice files using Replicatorg's latest version and load them to an SD Card.

Apply new kapton tape to the heated bed if needed. Next, on the Replicator front panel initiate warm up of the primary extruder. Proceed to level the bed using a sheet of paper and the on screen instructions. When this is complete, insert the SD card and select the file you wish to print.