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 and Slic3r are installed and configured. It has an SD card slot so you can also use it to build to card and print from that.

_Unplug_ and shut down when not using it.

Feel free to use the netbook and take it along when you transport printers.

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 (10/3/12)

File Types

STL

The slicing software needs your 3D model as an STL file before it can slice it. Slicing produces a file which has GCODE to describe the toolhead movements for each layer. It is important that your STL file only include one solid water tight object. Missing faces, open verticies and improper normal calculations will cause the slicer software to produce errors. You can fix some of this issues in an automated fashion by using NetFabb Basic, Blender (recalculate normals) and MeshLab's repair mode.

GCODE

This is a description of the tool path that is generated by a slicer. The file includes commands which instruct the printer how to move to produce the final object

S3G

Replicatorg converts a GCODE file into this reduced and compressed file type. This is equivalent to the GCODE but the smaller and easier to parse file type can be read off an SD card with less work. Use the build to SD card function in Replicatorg to produce this file.

Jargon

• Layer Height - The size of each layer the printer produces. This is limited at it's maximum by the size of the nozzle and at it's minimum by the amount of plastic produced and how much stretching occurs.
• Infill - The pattern and amount of plastic put inside the model to support it.
• Shells - The number of solid outer layers the model has
• Raft - A piece of plastic generated to stick to the print bed. This also includes support material for the object
• Filament - The plastic fed into the printer
• Extruder - The portion of a printer which
• Slic3r - Produces a GCODE file from an STL file
• Skeinforge - Produces a GCODE file from an STL file, built into Replicatorg
• Replicatorg - Produces a S3G file from GCODE and controls the printer
• OpenSCAD - 3D Solid Modeling software

Creamcheese Cupcake

This bots history

This machine started as a Cupcake with Gen3 electronics and Gen3 Extruder.

• 6/10 - Bot recieved
• 7/10 - Changed to makergear hot end
• 1/11 - The X and Y axis were made a low rider and changed to be quiet and more accurate.
• 5/12 - The DC extruder died during a 3D printing talk at Penguicon 2012. Switched to Stepper extruder
• 7/12 - Replaced stepper drivers with Pololu
• 10/12 - Accelerated

Notes on recent print problems

• 11/14 - Heated Build Platform stopped heating after ~2 hours of printing. Temporary solution = once your GCode is deleted, comment out the two M109 lines, and use Masking tape on the build platform. This seems to keep everything secure and help prevent warping. - JGW
• 11/18 - HPB working again.
  • HPB is not level to extruder head. Removed electrical tape from bottom. Right hand side is about 2mm to low. Put washers in between wooden platform and bottom nuts.
  • HPB is now almost perfectly level via eyeball
  • Trying various prints, there is still an issue where after ~2 hours of on/off printing, the temperature instantly drops to 0, and the makerbot disconnects. After this happened the first time, it proceeded to happen every few minutes, even when a print was not going but the temp was attempting to maintain @220/110
  • Desoldered all the recently work done by Senkow via the HPB wires. There were some solder bulbs on the HPB, and there some of the stranded core wires were attached, only a couple strands looked to be connected. No obvious bridging anywhere, but some loose strands might have been touching. Dirty dirty touching : )
  • Successful print. In the middle of testing 40% vs 70% infill at 500, 250, and 100 max accel

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 11/4!)

• 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 11/4
• Put the *.xml files in your replicatorg machines directory
• Place the 3 directories (filament, printer, print) and their contents into the Slic3r config directory.
  • Linux: /home/user/.slic3r (hidden)
  • OSX: /Library/Application Support/Slic3r/ (Not tested)
  • Windows 7 : C:\Users\Username\AppData\Roaming\Slic3r\

Printing with Slic3r and Replicatorg

-- Please use this checklist when using the printer. It helps us track settings and walks you through using the printer. [| Printer Checklist]

• 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 the GCODE file and replace all E's with A's (our extruder axis is A not E.)
• Delete the first G1 line in the file which should have nothing after it.
• Save the result.
• 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.

Changing Filament

Connect to the printer using Replicatorg and open the control panel. Heat the extruder up to 220c (for ABS) and the platform to 110c. When at temp, release the latch on the extruder (blue spring part) and pull the filament upward.

Take the new filament and using wire cutters make sure the end is flat. Feed it down the tube in the extruder and when at the bottom, fasten the latch. Using Replicatorg run the extruder forward until filament comes out. Continue to run it until the color changes to a solid color. Changing from dark to light filament requires significantly more time running the extruder forward to clean it out.

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.

Experimenting with the 3D printer configuration

Experimental Config

Contact

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

• Tyler W.
• Michael Sh.
• 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
• Sailfish Firmware.

How Do I run BlackBottom Cupcake?

Configure your machine like you would for Creamcheese cupcake.

When slicing use the following config: Blackbottom - 3MM ABS - BlackBottom

When connecting to Replicatorg connect using machine BlackBottom - Slic3r

Follow the same instructions as Creamcheese.

Contact

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

• Tyler W.
• Josh W.
• Michael Sh.

The Replicator

This Bots History

This bot was won by Backyard Brains and is for their use only. If you need to use it, contact a member of their staff or Tyler to setup a job for you.

How do I run the Replicator?

• Grab the latest version of Replicatorg.
• Slice using the Replicator Profile for the latest version of Skeinforge for the left or right extruder.
• Build to SD Card
• SD card into replicator
• In replicator menu, level the platform
• Preheat the head you wish to use.
• Select file from SD Card.

If the Kapton tape is ripping, reapply two new pieces from the roll and smooth them as you put them on. It is best for the bed to be cold when you do this.