Journal of 2/28/2015

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Two tons of crushed stone

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Bulbul Junior 3D Printer operation log – Day 5

http://www.thingiverse.com/thing:620461

Lea

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Slic3r – gcode generator
Prontface – 3D Printer control

Print setting
; generated by Slic3r 1.1.7 on 2015-02-22 at 20:31:47
; perimeters extrusion width = 0.40mm
; infill extrusion width = 0.40mm
; solid infill extrusion width = 0.40mm
; top infill extrusion width = 0.40mm
; support material extrusion width = 0.40mm
G21 ; set units to millimeters
G28 ; home all axes
G29
M106
G1 X0 Y0 Z65 F5000 ; lift nozzle
M104 S210
M109 S205 ; wait for temperature to be reached
G90 ; use absolute coordinates
G92 E0
M82 ; use absolute distances for extrusion

; filament used = 12362.7mm (29.7cm3)
; avoid_crossing_perimeters = 0
; bed_size = 170,170
; bed_temperature = 0
; bridge_acceleration = 0
; bridge_fan_speed = 100
; bridge_flow_ratio = 1
; brim_width = 1
; complete_objects = 0
; cooling = 1
; default_acceleration = 0
; disable_fan_first_layers = -1
; duplicate_distance = 6
; end_gcode = M104 S0 ; turn off temperature\nM106\nG28 X0 ; home X axis\nM84 ; disable motors\n
; external_perimeters_first = 1
; extruder_clearance_height = 20
; extruder_clearance_radius = 20
; extruder_offset = 0x0
; extrusion_axis = E
; extrusion_multiplier = 1
; fan_always_on = 1
; fan_below_layer_time = 60
; filament_diameter = 1.75
; first_layer_acceleration = 0
; first_layer_bed_temperature = 0
; first_layer_extrusion_width = 200%
; first_layer_speed = 25
; first_layer_temperature = 210
; g0 = 0
; gcode_arcs = 0
; gcode_comments = 0
; gcode_flavor = reprap
; infill_acceleration = 0
; infill_first = 0
; layer_gcode =
; max_fan_speed = 100
; min_fan_speed = 60
; min_print_speed = 10
; min_skirt_length = 1
; notes =
; nozzle_diameter = 0.4
; only_retract_when_crossing_perimeters = 1
; ooze_prevention = 1
; output_filename_format = [input_filename_base].gcode
; perimeter_acceleration = 0
; post_process =
; print_center = 0,0
; resolution = 0
; retract_before_travel = 2
; retract_layer_change = 0
; retract_length = 1.5
; retract_length_toolchange = 0
; retract_lift = 0.2
; retract_restart_extra = 0
; retract_restart_extra_toolchange = 0
; retract_speed = 15
; skirt_distance = 5
; skirt_height = 1
; skirts = 3
; slowdown_below_layer_time = 30
; spiral_vase = 0
; standby_temperature_delta = -5
; start_gcode = G28 ; home all axes\nM106\nG1 Z5 F5000 ; lift nozzle\n
; temperature = 190
; threads = 2
; toolchange_gcode =
; travel_speed = 400
; use_firmware_retraction = 0
; use_relative_e_distances = 0
; vibration_limit = 0
; wipe = 0
; z_offset = 0
; dont_support_bridges = 1
; extrusion_width = 0.4
; first_layer_height = 0.3
; infill_only_where_needed = 0
; interface_shells = 0
; layer_height = 0.2
; raft_layers = 1
; seam_position = nearest
; support_material = 1
; support_material_angle = 5
; support_material_enforce_layers = 5
; support_material_extruder = 1
; support_material_extrusion_width = 0
; support_material_interface_extruder = 1
; support_material_interface_layers = 3
; support_material_interface_spacing = 0.4
; support_material_interface_speed = 100%
; support_material_pattern = pillars
; support_material_spacing = 2.5
; support_material_speed = 60
; support_material_threshold = 0
; bottom_solid_layers = 3
; bridge_speed = 25
; external_perimeter_speed = 70%
; extra_perimeters = 1
; fill_angle = 45
; fill_density = 5%
; fill_pattern = honeycomb
; gap_fill_speed = 20
; infill_every_layers = 1
; infill_extruder = 1
; infill_extrusion_width = 0
; infill_speed = 60
; overhangs = 1
; perimeter_extruder = 1
; perimeter_extrusion_width = 0
; perimeter_speed = 30
; perimeters = 3
; small_perimeter_speed = 30
; solid_fill_pattern = rectilinear
; solid_infill_below_area = 70
; solid_infill_every_layers = 0
; solid_infill_extrusion_width = 0
; solid_infill_speed = 60
; thin_walls = 1
; top_infill_extrusion_width = 0
; top_solid_infill_speed = 50
; top_solid_layers = 3

458648 lines
12362.74mm of filament used in this print
The print goes:
– from -60.12 mm to 58.81 mm in X and is 118.94 mm wide
– from -48.95 mm to 45.95 mm in Y and is 94.89 mm deep
– from 0.00 mm to 100.50 mm in Z and is 100.50 mm high
Estimated duration: 502 layers, 5:25:00
Print started at: 20:42:47
-0.000 -0.000 -0.000 -0.510 -0.650 -0.650 -0.650
0.780 0.780 -0.010 -0.480 -0.700 -0.600 -0.600
2.110 0.800 0.060 -0.430 -0.650 -0.660 -0.430
2.030 0.940 0.230 -0.270 -0.520 -0.600 -0.410
2.310 1.270 0.540 0.060 -0.260 -0.310 -0.190
1.700 1.700 1.000 0.530 0.200 0.140 0.140
1.650 1.650 1.650 1.190 0.900 0.900 0.900
Print ended at: 01:28:13 and took 4:45:26
Setting hotend temperature to 0.000000 degrees Celsius.
>>> m106
SENDING:M106

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cDSC_0018 The right arm fell apart due to the poor support pillar.cDSC_0020

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Flaws and imperfection

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Infill density 5% caused crack.

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Layer height is 0.2 mm, nozzle diameter is 0.4 mm. The fingers look rough.

Is this resolution limit of Bulbul Junior?

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Bulbul Junior 3D Printer operation log – Day 4

http://www.thingiverse.com/thing:329076/#files

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Temperature calibration for 1.75mm PLA filament

http://www.thingiverse.com/thing:337957

RepRap Neo – How to set the perfect extruder temperature on your 3D Printer

Slic3r setting for good quality:
0.2 mm layer height
0.35 mm nozzle
0.4 mm extrusion width
1.75 mm PLA filament
0% Infill (33% for solid object)
3 Perimeters
3 Solid layers
2 mm Retract
16x microstepping
400 mm/s max travel
400 mm/s^2 acceleration
20 mm/s jerk

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Improvised warm air blower

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Bulbul Junior 3D Printer operation log – Day 3

I made a warm air blower using a 60W light bulb and a 12V DC fan to test heat effect on the 3D Printer. Last night before I went to sleep, I checked the temperature of 60W light bulb using IR thermometer. It went upto 165+ Celsius degrees and maintain it. So I thought it could be use as a heating element for an experiment.

12V DC fan on 5V blows gentle air through the light bulb and this lucrative warm air blower raise the temperature around the print bed over 30 degrees, which is ten degrees higher than room temperature.

Once I install complete enclosure made out of cardboard, I think the temperature of print bed would be around 40 degrees.

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I printed five to six cubes for dimensional calibration.

Source: http://whatskenmaking.com/2014/06/16/object-size-calibration-in-a-delta-printer/

new DELTA_DIAGONAL_ROD = measured_length / target_length * original DELTA_DIAGONAL_ROD

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What makes the first layer wider than other layers?

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The warm air blower could raise the temperature near the print bed over 33 Celsius degrees. But I’ve found the first layer wouldn’t stick well. So I applied the glue stick on the print bed before printing, and it worked like a magic.

After the key fob finished printing, it glued so tight on the tape that I had to rip off the tape. I’ll try it again for next printing object.

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Bulbul Junior 3D Printer operation log – Day 2

Clogged heat break in day 1

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Stretched 1.75mm PLA filament in Day 1

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One of the diagonal rod fell off yesterday. I glued it with metal epoxy this time.

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Back to print again?

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Yes.

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The first layer looks fantastic.

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I got fed up when it happened.cDSC_0203

Temperature was 215 Celsius degrees. cDSC_0205

Second attempt of printing failed again less than five minutes. The layers separated from print bed.cDSC_0207

Then in the third attempt there was filament blockage in hotend again.
I removed this piece out of the heat break.
I removed nozzle and run the heater at 190 degrees without fan on to soften the filament pieces that clogged the heat break. Then after few poking the heat break channel underneath it by 1.5 mm of allen key, pushed out to the top of hotend.
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The modified original effector developed a crack.
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Bulbul Junior 3D Printer operation log – 1

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Building of Mini Kossel 3D Printer – 25 (final), birthday of Bulbul Junior 3D Printer!

I named this Kossel Mini as Bulbul Junior yesterday. Today was its offical birthday. The version is m00.f01. m indicates modification of mechanical part, f is for firmware upgrade or modification. It’s now fully functional Reprap 3D Printer. It’s been so lonely, hit the bottom really hard from time to time. At one point I questioned my ability of problem solving. Fortunately I managed to build functional Reprap 3D Printer. I believe in 3D Printer is very powerful tool that opens up many possibilities to any individual who has strong desire to exercise, advance practical knowledge and skills in creative field, especially mechanical engineering, machine design, and solid visual arts.

Kossel Effector E3D V6 Bowden 1.75mm (Includ autoprobing)

http://www.thingiverse.com/thing:439497

Kossel Effector E3D V6 Bowden 1.75mm (Includ autoprobing)

I downloaded four STL files from above link and have printed all four printed parts successfully. Prontface screen shot during the print session of the effector for E3D V6 Hotend. Debian Wheey hasn’t provided Prontface package yet. I downloaded the Python source code and have been using it. It has critical errors for 3D view but 2D view is functional.

I used 1.75mm PLA filament.

I flipped the effector in Sli3r to generate the gcode file.

The effector

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When the PTFE tube pops out, printing operation is technically finished. It popped out when the pressure built up by 5.18:1 geared stepper motor below it once. I was desperate to avoid this kind of failure due to flawed design and luckily found out information that lubricating the filament with edible Canola oil reduces the friction inside the tube. So it’s cheap and effective way of preventing filament jam while in printing.

I found a bottle of Canola oil in the kitchen and put 20 to 30 cc of the oil in a small dish. And I started manually lubricating section of filament that is pulled into the extruder. It looked funny and silly but the job had to be done.

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Printing of the effector is done.cDSC_0127

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Dimension of the effector was 60.73mm x 54.19mm x 18.00mm

Dimension of the printed effector was 60.80mm x 53.60mm x 18.10mm

Printing other three parts

Prontface log
Connecting...
start
Printer is now online.
echo: External Reset
Marlin 1.0.0
echo: Last Updated: Feb 15 2015 12:25:53 | Author: (jcrocholl, Blomker, hughe, Bulbul Junior m00.f01)
Compiled: Feb 15 2015
echo: Free Memory: 3786 PlannerBufferBytes: 1232
echo:Hardcoded Default Settings Loaded
echo:SD init fail
Setting hotend temperature to 215.000000 degrees Celsius.
>>> m302
SENDING:M302
>>> m106
SENDING:M106
>>> m106 s100
SENDING:M106 S100
Loading file: /home/penguin/Workshop/3D_Printer/Kossel_Mini/object_models/Kossel_Effector_E3D_V6_Includ_autoprobing/KosselEffectorE3DClampProb.gcode
Loaded /home/penguin/Workshop/3D_Printer/Kossel_Mini/object_models/Kossel_Effector_E3D_V6_Includ_autoprobing/KosselEffectorE3DClampProb.gcode, 46435 lines
2819.57mm of filament used in this print
The print goes:
- from -33.68 mm to 33.68 mm in X and is 67.36 mm wide
- from -43.36 mm to 43.16 mm in Y and is 86.52 mm deep
- from 0.00 mm to 16.20 mm in Z and is 16.20 mm high
Estimated duration: 80 layers, 0:49:54
Extruding 1.000000mm of filament.
Extruding 1.000000mm of filament.
Print started at: 19:03:57
0.090 0.090 0.090 0.040 -0.050 -0.050 -0.050
0.350 0.350 0.190 0.010 -0.080 -0.110 -0.110
0.710 0.400 0.230 0.050 -0.110 -0.150 -0.160
0.730 0.380 0.180 -0.020 -0.150 -0.180 -0.200

Effector clamp

Auto level probe mount

Clip for the probe – 3mm allen key

I generated one gcode file that contains the other three parts to save time using sli3r.

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The printing quality definitely improved. cDSC_0150

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Dimension of probe clip is 5.50mm x 10.75mm x 5.50mm

Dimension of printed clip is 5.70mm x 10.85mm x 5.80mm

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Dimension of probe mount is 31.58mm x 30.00mm x 16.24mm

Dimension of printed probe mount is 31.60mm x 30.00 mm x 16.35mm

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Dimension of the clamp is 12.05mm x 34.00mm x 9.50mm

Dimension of the printed clamp is 12.00mm x 33.90mm x 9.80mm

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I have effector assembly kit for E3D V6 Hotend now. Isn’t it amazing?

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The second printed part I failed spectacularly due to mechanical problem one or two days ago. cDSC_0169

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