A dark dot on every photo

I don’t remember when this dark dot appeared on photo. I found it few days ago. I cleaned the Nikon lens and reflector mirror to remove it. It was still existed at the same spot even after shooting photos on 300 mm telephoto lens.

There was a dust on the image sensor which I would not expect. Cleaning procedure I did:
1. Remove the lens.
2. Put in Manual mode and set exposure time for 10s.
3. Press the shutter button.
4. Blow air on the rectangular image sensor while checking dust
5. Repeat step 2 to step 4 till image sensor’s surface is spotless.
6. Take sample photos and check the dark dot.

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Function names in OpenSCAD

Function name starts with under bar or number work.

module __function_name()
{
cylinder(h=10, r=3, center=true);
}

module 1function_name()
{
translate([15, 0, 0]) sphere(r=4, center=true);
}

__function_name();
1function_name();

function_name_test

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RepRapPro Fisher – 4

I figured it out why the shortage of filament extrusion last night finally.
The right amount of force against filament at the geared shaft and idler bearing requires to provide good retraction. Extruding filament after specified length of filament retraction, i.e. 3.5 mm in this case, demands stronger force due to the pressure and friction in Bowden tube.

When the extruder can’t push filament, the geared shaft grinds stuck filament and it ruins entire printing.

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In Fisher’s extruder drive, the squeezing force on filament is regulated by spring loaded lever. As I set the bolt length between lever and bolt head to 18 mm, filament starvation began to disappear.

Another important one is that melting temperature of filament affects extruding force.
Lower temperature needs stronger squeezing force at the extruder drive.

Failed Robot
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No retraction, 215C
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Retraction 2 mm, 210C (lower half), 205C (upper half)
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Retraction torture test, retraction 3.5 mm, 215C
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Retraction torture test, 205C

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RepRapPro Fisher – 3

Excessive rubbing between the bowden tube and Y endstop cable caused disconnection one of the endstop terminals.

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7:56:10 AM M32 Robot.g
File Robot.g selected for printing
7:54:03 AM G32
Calibrated 4 factors using 4 points, deviation before 0.640 after 0.000
7:50:46 AM Connection established!

I printed the sample object, Robot.g, supplied by RepRapPro.


; generated by Slic3r 1.2.9 on 2015-07-01 at 10:51:31

; external perimeters extrusion width = 0.40mm
; perimeters extrusion width = 0.40mm
; infill extrusion width = 0.40mm
; solid infill extrusion width = 0.40mm
; top infill extrusion width = 0.40mm

M107
M83
T0
M116
G1 X0 Y0 Z4 F4000
G30
G1 Z0.35 F4000

G21 ; set units to millimeters
G90 ; use absolute coordinates
M83 ; use relative distances for extrusion

; retract_layer_change = 1
; retract_length = 3.5
; retract_length_toolchange = 10
; retract_lift = 0.4
; retract_restart_extra = 0
; retract_restart_extra_toolchange = 0
; retract_speed = 50

My Fisher showed filament starvation as it was printing upper part of the robot, which is improper retraction setting.

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RepRapPro Fisher – 3

Loaded the 1.75 filament and tested functions of Hotend and extruder as per the commissioning instruction.

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Commissioning

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RepRapPro Fisher – 2

It comes with printed round bar that holds a 0.5kg spool on the side panel.
I disliked it and made a simple spool holder that takes 1 kg filament spool I have.

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M6x100 bolt x1
M6 nut x2
M6 washer x2
67 mm length of Spacer
Two M8x100 bolts and six M8 bolts hold two triangle panel.
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I noticed the timing belt rubs side wall of belt tensioner all the time. It will eats up the side walls and eventually create mechanical issue within few hundred hours of operation. I replaced 623 bearing of the belt tensioners with F623 bearing.

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A base made out of MDF

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Laser cutting cost of Fisher frames and parts

Plastic part has reliability problem. I have zero intend to spend time and energy for troubleshooting inevitable failures of many plastic parts of Fisher. RepRapPro introduces Fisher as entry-level, low cost 3D Printer. One of main reasons I bought Fisher Beta kit was to know and learn about how experts in RepRap 3D Printer industry design, make product.

Base plate, ss (steel), 5t (5 mm thickness), 9,300 KRW

Top plate, 9,500 KRW

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Front panel x2, 6,500 KRW * 2

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Side panel, 7,500 KRW

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I need to supply aluminium plate to the laser cutting company.

Print bed, 5,000 KRW

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Diagonal rod x12 * 2,000 KRW

Effector plate, middle, 3,700 KRW

Effector plate, top, 3,700 KRW

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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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