RepRapPro Fisher Delta

This one is the first 3D Printer kit I bought out of curiosity. It took me past three days to build it. Now I have two Reprap 3D Printers. Bulbul Junior is out of commission due to serious problem of prototype parts I had installed. I’ll post the story later.

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Commissioning

The instruction assumes Windows user as usual for making the firmware microSD card. I only use Debian so I had to figure it out. Compared to few mouse clicks of file manager in Windows to do the job, it seems awkward and inefficient.

Check the micro SD card.
$ sudo fdisk -l

Disk /dev/sdc: 3909 MB, 3909091328 bytes
102 heads, 37 sectors/track, 2023 cylinders, total 7634944 sectors
Units = sectors of 1 * 512 = 512 bytes3:51:48 AM Disconnected.
3:45:20 AM G31
0
3:40:57 AM M119
Endstops - X: not stopped, Y: not stopped, Z: not stopped
3:40:48 AM M119
Endstops - X: not stopped, Y: not stopped, Z: at max stop
3:40:38 AM M119
Endstops - X: not stopped, Y: at max stop, Z: not stopped
3:40:19 AM M119
Endstops - X: at max stop, Y: not stopped, Z: not stopped
3:38:58 AM M119
Endstops - X: not stopped, Y: not stopped, Z: not stopped
3:31:01 AM Connection established!
3:30:54 AM Disconnected.
3:13:28 AM Connection established!
3:13:28 AM Page Load complete!
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x00000000

Device Boot Start End Blocks Id System
/dev/sdc1 8192 7634943 3813376 b W95 FAT32

Mound the micro SD card.

$ sudo mount /dev/sdc1 ./sandisk/
penguin@theblue:/media$ cd sandisk/
penguin@theblue:/media/sandisk$ ls
penguin@theblue:/media/sandisk$ ls -lh
total 0

penguin@theblue:/media/sandisk$ df
Filesystem 1K-blocks Used Available Use%I intend to focus on setting up Fisher 3D Printer.
I intend to focus on setting up Fisher 3D Printer.
Mounted on
/dev/sda1 148256176 116094704 24623760 83% /
udev 10240 0 10240 0% /dev
tmpfs 791956 896 791060 1% /run
tmpfs 5120 4 5116 1% /run/lock
tmpfs 2495260 736 2494524 1% /run/shm
/dev/sda2 945144 70840 825460 8% /boot
/dev/sdc1 3809280 32 3809248 1% /media/sandisk

Copy the offical Fisher firmware files to the SD card.

$ sudo cp -R . /media/sandisk

Verify the files in the SD card.

$ ls -alR /media/sandisk/
/media/sandisk/:
total 196
drwxr-xr-x 7 root root 32768 Aug 5 02:59 .
drwxr-xr-x 7 root root 4096 Dec 24 2014 ..
drwxr-xr-x 2 root root 32768 Aug 5 02:59 firmware
drwxr-xr-x 2 root root 32768 Aug 5 02:59 gcodes
drwxr-xr-x 2 root root 32768 Aug 5 02:59 macros
drwxr-xr-x 2 root root 32768 Aug 5 02:59 sys
drwxr-xr-x 6 root root 32768 Aug 5 02:59 www

/media/sandisk/firmware:
total 288
drwxr-xr-x 2 root root 32768 Aug 5 02:59 .
drwxr-xr-x 7 root root 32768 Aug 5 02:59 ..
-rwxr-xr-x 1 root root 222472 Aug 5 02:59 RepRapFirmware-1.09c-dc42.bin
/media/sandisk/gcodes:
total 960
drwxr-xr-x 2 root root 32768 Aug 5 02:59 .
drwxr-xr-x 7 root root 32768 Aug 5 02:59 ..
-rwxr-xr-x 1 root root 891169 Aug 5 02:59 Robot.g

/media/sandisk/macros:
total 5123:51:48 AM Disconnected.
3:45:20 AM G31
0
3:40:57 AM M119
Endstops - X: not stopped, Y: not stopped, Z: not stopped
3:40:48 AM M119
Endstops - X: not stopped, Y: not stopped, Z: at max stop
3:40:38 AM M119
Endstops - X: not stopped, Y: at max stop, Z: not stopped
3:40:19 AM M119
Endstops - X: at max stop, Y: not stopped, Z: not stopped
3:38:58 AM M119
Endstops - X: not stopped, Y: not stopped, Z: not stopped
3:31:01 AM Connection established!
3:30:54 AM Disconnected.
3:13:28 AM Connection established!
3:13:28 AM Page Load complete!
drwxr-xr-x 2 root root 32768 Aug 5 02:59 .
drwxr-xr-x 7 root root 32768 Aug 5 02:59 ..
-rwxr-xr-x 1 root root 1465 Aug 5 02:59 bed4.g
-rwxr-xr-x 1 root root 1464 Aug 5 02:59 bed4.g~
-rwxr-xr-x 1 root root 1466 Aug 5 02:59 bed4meas.g
-rwxr-xr-x 1 root root 1466 Aug 5 02:59 bed4meas.g~
-rwxr-xr-x 1 root root 1728 Aug 5 02:59 bed7.g
-rwxr-xr-x 1 root root 820 Aug 5 02:59 bed7hex.g
-rwxr-xr-x 1 root root 824 Aug 5 02:59 bed7hexmeas.g
-rwxr-xr-x 1 root root 39 Aug 5 02:59 E motors off
-rwxr-xr-x 1 root root 34 Aug 5 02:59 Extrude 5mm
-rwxr-xr-x 1 root root 31 Aug 5 02:59 INITIALISE
-rwxr-xr-x 1 root root 123 Aug 5 02:59 Load filament

Unmount the SD card before commissioning

$ sudo umount /media/sandisk

Below is the console output Gcode commands I executed on Duet Web interface.

3:51:48 AM Disconnected.
3:45:20 AM G31
0
3:40:57 AM M119
Endstops - X: not stopped, Y: not stopped, Z: not stopped
3:40:48 AM M119
Endstops - X: not stopped, Y: not stopped, Z: at max stop
3:40:38 AM M119
Endstops - X: not stopped, Y: at max stop, Z: not stopped
3:40:19 AM M119
Endstops - X: at max stop, Y: not stopped, Z: not stopped
3:38:58 AM M119
Endstops - X: not stopped, Y: not stopped, Z: not stopped
3:31:01 AM Connection established!
3:30:54 AM Disconnected.
3:13:28 AM Connection established!
3:13:28 AM Page Load complete!

So far the machine works fine which is rewarding, also boosting my confidence as RepRap 3D Printer builder.

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Fisher_delta_3D_Printer1

Fisher_delta_3D_Printer2

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Journal of 7/26/2015

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Spring loaded steel ball joint system

Fish line was too weak. So I tried a different string and it worked out for now.

I reduced the build diameter from 150.00 mm to 70.00 mm at the moment due to design flaws of the carriage and shape of effector plate. How to maximize the build diameter in this configuration?

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Weight of the effector assembly is 127.60 grams.
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7/22/2015

Without layer fan printing a small profile model is hard.
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I lowered height of ball seat on the carriage by 10.0 mm to increase build diameter.
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4.00 mm thickness of effector plate develops bend at each point where the spring pulls. I’m working on new effector that fixes the flaws and has small profile so that final build diameter over 150.00 mm. Build diameter of Bulbul Junior is 120.00 mm at the moment.
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7/31/2018

The effector plate is in bad shape. I’ve noticed that every two or three days the nozzle moves up 0.2 to 0.3 mm.

I gonna install new effector pretty soon.
effector_v2_test

effector2_test_render

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Mastering bridge

I performed E steps fine tuning. The original E steps was 462.80. Final E steps became E443.09 going through eight to ten calibration objects.

Infill 95%, Solid layer
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Solid layer, Infill 95%
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E Steps Fine Tuning

Now, with everything very close to ideal values, we can finally dial E steps in that final little bit!
Find an object with flat tops on a number of levels, such as this cube stack test (scale this object by 250% after loading in Slic3r)
Slice at 95% rectilinear infill. Use the lowest layer height you’re comfortable with – the lower the layer height used for this test, the finer your resulting E steps calibration will be. I use 0.2mm for first run, and if I’m feeling ambitious I’ll repeat this process at 0.1mm.
Print.
Ignore the first 5-6 layers because they’re too sensitive to the exact height of the first layer. If it’s obviously over-filling or under-filling, alter E steps or Z=0 point and restart the print.
Observe infill. If you can’t see tiny little gaps between the lines, reduce E steps by 0.5% every 2 layers until you can see tiny gaps.
Observe solid top layers. If you can see tiny gaps, increase E steps by 0.5% every 2 layers until there’s no gaps in the top.
Send the new E steps to your printer with M92 Ennn without even pausing the print – you will see the result in a couple of layers when the change is this small.
Goto 5 until the infill has tiny gaps AND the solid top layers do not.
Now, your E steps value is extremely fine-tuned! Save this value in your firmware’s configuration and flash to make permanent.
[edit]Finish

Now print your favourite calibration piece (e.g., ultimate calibration) and see how it measures!

Temperature: 185C
Layer fan speed: 100%

Slic3r setting:
Layer height: 0.2 mm
Bridging speed: 10 mm/s

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Previous bridging test

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Hyper 212 Evo by Cooler master

It’s a huge fan. I was overwhelmed by its size when it arrived.

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The installation instruction was unclear and I had to take off it once after finding 50 Celsius degrees in idle run. The square hole of the contact plate was too small so that it seat on top of the processor leaving 2 mm to 1.5 mm of gap.

I used two M5 washers instead two pieces of aluminium block for making full contact between processor and heat sink.

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I think I spent good few hours to install the cooler.

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It lowered CPU temperature five to ten Celsius degrees compared to the stock AMD cooler. The cooling fan runs around at 1,000 to 1,200 RPM, which is half the speed of the stock cooler. The computer runs quieter.

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Layer fan and a dummy object makes printing difficult models.

I opened an account on 3D Hubs as 3D Printing service provider. The first order I had to print the Marvin. It looked a simple model but I had to print over sixteen samples before I managed to print an acceptable Marvin.

Filament: PLA 1.75 mm
Layer height: 50 microns (0.05 mm)
Printing speed: 60 mm/s
(I set the printing speed to 20 mm/s on bottom and top part.)

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The hook on top of Marvin gave me a lot of frustration because extremely slow printing or fast, 10 seconds of layer cooling time by Cool lift failed to produce decent shape. Cool lift left messy strings around the hook.

I thought ‘Is that all?’ and went out for Internet searching to find out how other users handle the Marvin. I forgot which site that a simple technique using a dummy object, which provide enough cooling time of tight layer such as the hook. So I added a cube object beside the Marvin on build platform in Cura.

The cooling time of target object’s layer is determined by travel speed and distance from the object, and shape of dummy object. Suppose travel speed is set 250 mm/s, five seconds of cooling time is derived by following formula.

Speed = distance / time
time = distance / speed
5 = distance / speed
distance = 5 * speed
distance = 5 s * 250 mm/s
= 1,250 mm

The nozzle makes a round trip so half of 1,250 mm is the distance between two objects, which is 625 mm. And we add average printing time of one layer of the dummy object to get the desirable cooling time of the target object.

By three to four test printing like below, I found dummy object’s size and separating distance from Marvin.
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Near finish of a successful Marvin printing.
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Air flow near the nozzle affects printing quality too. The ideal setup is to direct air tip of the nozzle in circular pattern.  The oval fan duct I installed today afternoon produced better quality of Marvin with 0.1 mm layer height, compared to the above one.

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The layer fan is magic secret!

http://www.thingiverse.com/download:62984

Last month I tried to print it and realized that my Bulbul Junior couldn’t make it due to lack of cooling power. Later on I learned that to have good quality in PLA filament, layer fan is must-have device.

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Yesterday I managed to install the layer fan. (http://www.thingiverse.com/thing:540716) It improved printing quality instantly. More over it literally moved capability of Bulbul Junior to next level. Printing sphere, overhang object were impractical.

Printing speed of the left side was up to 5 mm/s.
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Normal printing speed over 30 mm/s created failed cups.
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I’ve had 3D Printing fever for few days. Sometimes replacement of broken part required Marlin firmware hack. One week ago thermistor of E3D V6 hotend got broken. The thickness of thermistor lead is 0.2 mm according to the data sheet. I would take two to three weeks for getting the thermistor kits from E3D company in England. So I decided to install other thermistor I could buy in domestic market. I found a thermistor rating -40C to 250C made by Korean company from an online electronic shop.

Configuration.h

// 20 is 20k Samkyung NTC-20KGJG (4.7k pullup)
// 60 is 100k Maker's Tool Works Kapton Bed Thermister
//
// 1k ohm pullup tables - This is not normal, you would have to have changed out your 4.7k for 1k
// (but gives greater accuracy and more stable PID)
// 51 is 100k thermistor - EPCOS (1k pullup)
// 52 is 200k thermistor - ATC Semitec 204GT-2 (1k pullup)
// 55 is 100k thermistor - ATC Semitec 104GT-2 (Used in ParCan) (1k pullup)

// Custom thermistor
#define TEMP_SENSOR_0 20 // 5 (E3D V6 Hotend)

thermistortables.h

// Thermistor lookup table for Marlin
// ./createTemperatureLookup.py --rp=4700 --t1=25.0:20000.0 --t2=115.0:877.52 --t3=250.0:54.44 --num-temps=60

#if (THERMISTORHEATER_0 == 20) || (THERMISTORHEATER_1 == 20) || (THERMISTORHEATER_2 == 20) || (THERMISTORBED == 20)
const short temptable_20[][2] PROGMEM = {
{97, 284},
{105, 278},
{114, 272},
{124, 266},
{135, 260},
{147, 254},
{161, 248},
{176, 242},
{193, 230},
{212, 224},
{233, 218},
{257, 212},
{284, 206},
{315, 200},
{349, 194},
{388, 188},
{433, 182},
{484, 176},
{542, 170},
{609, 164},
{685, 158},
{773, 152},
{874, 146},
{991, 140},
{1126, 134},
{1282, 128},
{1462, 122},
{1672, 116},
{1914, 110},
{2195, 104},
{2519, 98},
{2892, 92},
{3320, 86},
{3809, 80},
{4363, 74},
{4985, 68},
{5675, 62},
{6431, 56},
{7245, 50},
{8105, 44},
{8996, 38},
{9897, 32},
{10784, 26},
{11636, 20},
{12431, 14},
{13153, 8},
{13792, 2},
{14341, -4}
};
#endif

Fast retraction causes early failure of Bowden drive. PTFE tube of extruder wears out. Once it starts popping out middle of printing, it’s game over. Two times in a row for two days, heavy duty Push fit that has six tiny metal teeth chewed up end of the PTFE tube on extruder. I got so pissed off by it, frustrated about stupid or silly design flaw. I started thinking how to eliminate the movement of PFTE tube on extruder, came up with gluing the tube and Push fit altogether permanently.

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The first order was effector for E3D V6 hotend and I made it for free. Printed parts kit of Kossel Mini for 2020 aluminium extrusion. It’s the second order delivery. I gonna charge service fee on it. I set printing rate about 2,000.00 KRW/hour that covers operation cost of Bulbul Junior for a while. As soon as I’ll run second Reprap 3D Printer, I’ll start make some money out of 3D printing business.

Within few months I gonna have three Deltabot 3D Printers. By end of this year I plan to build at least one SLA 3D Printer by myself, including 3D scanner system that uses Open Source photogrammetry software.

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Bulbul Junior in action

Six endstops, 2020 Kossel Mini kit

Stepper motor mount, 2020 Kossel Mini kit

40 mm layer fan duct kit

Turbine blade for blower motor

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