Category Archives: Printing

Printing

Huxley Roxrap : First Print

A nice way of ending a productive weekend:  The Huxley-class printer I have been working on produces it’s first print!

Designated “Roxrap”, after the various parts used that were salvaged from an old Xerox laser printer, this is my first printer produced from my Prusa. It’s a mish-mash of the existing Huxley/Mini-Mendel designs (eMaker, TechZone, Mini-Mendel & the RepRap Huxley) plus some parts I designed myself.  It will be the printer where I can experiment with designs without fear of suddenly having no printer available if something goes wrong.

The first print, a 20mm cube, is absolutely terrible of course.  There is much calibration to be done: the frame wobbles, the X carriage shifts, the extruder drive is inconsistent and incorrectly configured, but the fact that it produced something without blowing up is a win for me.

 

Printing

Perfecting Pulleys Redux

The self proclaimed “pulley nirvana” from a previous post didn’t last long. It seems that changing extruder, filament, or perhaps the weather, had caused a regression in the pulley prints I need for my upcoming Huxley/Mini-Mendel, even though the same gcode was used – with the cool setting and a slower feed/flow rate. The print goes fine until a third through the spurs of the gear, and then the flow splutters and starts, causing a very deformed (and unusable) gear.

 

At first I thought the cause might lie in too high a temperature, and so I reduced the hot end temperature to 180°C (from 195°C), and also placed a desktop fan adjacent to the bed, on the lowest setting. The results were still poor.

It seems that the Dimension module in Skeinforge was retracting the filament too much (because the speed was so much lower, it had more time to retract) and consequently the beginning of each layer on the spurs was receiving less and less material. Hence the deformity. Changing this value from 1.3 to 0.2 brought about much better results.

Not perfect, but usable, and a step in the right direction.

Below are the Skeinforge settings used in case they are useful.

Skeinforge Settings

Important
Layer Thickness (mm): 0.4
Perimeter Width over Thickness (ratio): 1.4
Infill Solidity (ratio): 0.3
Feed Rate (mm/s): 25.0
Flow Rate Setting (float): 25.0
dimension
Absolute Extrusion Distance True
Relative Extrusion Distance False
Extruder Retraction Speed (mm/s): 20.0
Filament Diameter (mm): 2.85
Filament Packing Density (ratio): 1.0
Retraction Distance (millimeters): 0.2
Restart Extra Distance (millimeters): 0.0
More...
carve
Add Layer Template to SVG True
Extra Decimal Places (float): 2.0
Import Coarseness (ratio): 1.0
Infill in Direction of Bridge True
Layer Thickness (mm): 0.4
Layers From (index): 0
Layers To (index): 912345678
Correct Mesh True
Unproven Mesh False
Perimeter Width over Thickness (ratio): 1.4
SVG Viewer: webbrowser
chop
Add Extra Top Layer if Necessary True
Add Layer Template to SVG True
Extra Decimal Places (float): 2.0
Import Coarseness (ratio): 1.0
Layer Thickness (mm): 10.0
Layers From (index): 0
Layers To (index): 999999999
Correct Mesh True
Unproven Mesh False
Perimeter Width (mm): 2.0
SVG Viewer: webbrowser
comb
Activate Comb True
cool
Activate Cool True
Bridge Cool (Celcius): 1.0
Orbit False
Slow Down True
Maximum Cool (Celcius): 2.0
Minimum Layer Time (seconds): 10.0
Minimum Orbital Radius (millimeters): 10.0
Name of Cool End File: cool_end.gcode
Name of Cool Start File: cool_start.gcode
Turn Fan On at Beginning True
Turn Fan Off at Ending True
dimension
Activate Dimension True
Absolute Extrusion Distance True
Relative Extrusion Distance False
Extruder Retraction Speed (mm/s): 20.0
Filament Diameter (mm): 2.85
Filament Packing Density (ratio): 1.0
Retraction Distance (millimeters): 0.2
Restart Extra Distance (millimeters): 0.0
fill
Activate Fill: True
Diaphragm Period (layers): 100
Diaphragm Thickness (layers): 0
Extra Shells on Alternating Solid Layer (layers): 0
Extra Shells on Base (layers): 0
Extra Shells on Sparse Layer (layers): 0
Grid Circle Separation over Perimeter Width (ratio): 0.2
Grid Extra Overlap (ratio): 0.1
Grid Junction Separation Band Height (layers): 10
Grid Junction Separation over Octogon Radius At End (ratio): 0.0
Grid Junction Separation over Octogon Radius At Middle (ratio): 0.0
Infill Begin Rotation (degrees): 45.0
Infill Begin Rotation Repeat (layers): 1
Infill Odd Layer Extra Rotation (degrees): 90.0
Grid Circular False
Grid Hexagonal False
Grid Rectangular False
Line True
Infill Perimeter Overlap (ratio): 0.15
Infill Solidity (ratio): 0.3
Infill Width over Thickness (ratio): 1.3
Solid Surface Thickness (layers): 1
Lower Left True
Nearest False
Infill > Loops > Perimeter False
Infill > Perimeter > Loops False
Loops > Infill > Perimeter False
Loops > Perimeter > Infill True
Perimeter > Infill > Loops False
Perimeter > Loops > Infill False
home
Activate Home True
Name of Homing File: homing.gcode
inset
Add Custom Code for Temperature Reading True
Bridge Width Multiplier (ratio): 1.0
Ascending Area True
Descending Area False
Overlap Removal Width over Perimeter Width (ratio): 0.6
Turn Extruder Heater Off at Shut Down True
limit
Activate Limit True
Maximum Initial Feed Rate (mm/s): 80.0
Maximum Z Feed Rate (mm/s): 1.0
multiply
Activate Multiply: True
Center X (mm): 50.0
Center Y (mm): 50.0
Number of Columns (integer): 1
Number of Rows (integer): 1
Separation over Perimeter Width (ratio): 15.0
preface
Name of End File: end.gcode
Name of Start File: startMendel05l04PLA.gcode
Set Positioning to Absolute True
Set Units to Millimeters True
Start at Home False
Turn Extruder Off at Shut Down False
Turn Extruder Off at Start Up False
raft
Activate Raft True
Add Raft, Elevate Nozzle, Orbit: True
Base Feed Rate Multiplier (ratio): 1.0
Base Flow Rate Multiplier (ratio): 1.0
Base Infill Density (ratio): 0.5
Base Layer Thickness over Layer Thickness: 2.0
Base Layers (integer): 0
Base Nozzle Lift over Base Layer Thickness (ratio): 0.2
Initial Circling: False
Infill Overhang over Extrusion Width (ratio): 0.05
Interface Feed Rate Multiplier (ratio): 1.0
Interface Flow Rate Multiplier (ratio): 1.0
Interface Infill Density (ratio): 0.5
Interface Layer Thickness over Layer Thickness: 1.0
Interface Layers (integer): 0
Interface Nozzle Lift over Interface Layer Thickness (ratio): 0.45
Name of Support End File: support_end.gcode
Name of Support Start File: support_start.gcode
Object First Layer Feed Rate Infill Multiplier (ratio): 0.4
Object First Layer Feed Rate Perimeter Multiplier (ratio): 0.4
Object First Layer Flow Rate Infill Multiplier (ratio): 0.4
Object First Layer Flow Rate Perimeter Multiplier (ratio): 0.4
Operating Nozzle Lift over Layer Thickness (ratio): 0.5
Raft Additional Margin over Length (%): 1.0
Raft Margin (mm): 3.0
Support Cross Hatch False
Support Flow Rate over Operating Flow Rate (ratio): 1.0
Support Gap over Perimeter Extrusion Width (ratio): 1.0
None True
Empty Layers Only False
Everywhere False
Exterior Only False
Support Minimum Angle (degrees): 60.0
speed
Activate Speed: True
Add Flow Rate: True
Bridge Feed Rate Multiplier (ratio): 1.0
Bridge Flow Rate Multiplier (ratio): 1.0
Duty Cyle at Beginning (portion): 1.0
Duty Cyle at Ending (portion): 0.0
Feed Rate (mm/s): 25.0
Flow Rate Setting (float): 25.0
Orbital Feed Rate over Operating Feed Rate (ratio): 0.5
Perimeter Feed Rate over Operating Feed Rate (ratio): 0.7
Perimeter Flow Rate over Operating Flow Rate (ratio): 0.7
Travel Feed Rate (mm/s): 30.0
stretch
Activate Stretch True
Cross Limit Distance Over Perimeter Width (ratio): 5.0
Loop Stretch Over Perimeter Width (ratio): 0.11
Path Stretch Over Perimeter Width (ratio): 0.0
Perimeter Inside Stretch Over Perimeter Width (ratio): 0.64
Perimeter Outside Stretch Over Perimeter Width (ratio): 0.1
Stretch From Distance Over Perimeter Width (ratio): 2.0

 

Printing

Lego Minifig

X2 Normal Size

Printing

Finding Problems, Resolving Problems

An eventful few days, largely dealing with wear and tear maintenance issues.

X End Idler Split

It seems that whilst using lubricant on the Z axis rods was a reasonable idea it soaked into the X End Idler and caused weakness between layers (I believe). This in turn resulted in a slight split and the head of the hot end ploughing through the last few layers of a print.


Attempting to realign the print (of a gear) seemed to work fine, but closer inspection shows it was pretty skewed and is not usable as it stands.

Luckily the split didn’t grow, or affect subsequent prints, so I could print out it’s replacement.

Perfecting the Pulley

So my circles were coming out oval and I still hadn’t printed the perfect pulley.  Suspecting that a replacement pulley with a dent in the teeth was the cause of the oval problem I brought the original out of retirement with a quick hack.  This allowed me to print a few pulleys, and this time I achieved pulley nirvana.  The secret? Cool in Skeinforge.  It seems obvious now, but my previous attempts to utilise the cool module didn’t work because I was using “orbit”. Changing this to “slow down” meant that the spurs and teeth were laid down much slower, and hence with much less deformities!

Loose X Belt

Having more faith in the X pulley I was expecting perfect(ish) circles, but no joy.  A bit more observation made me realise that the X belt was wobbling quite a bit at the apex of each turn. I had thought the belt was tight enough, but it seems it was not – and tightening it so it “twangs” when tapped results in much better circles.

 

Extruder Printing

Building Matt Robert’s Compact Geared Extruder

I wanted an extruder to use for my experimental hot ends so I took advantage of the long weekend and had a go at Matt Robert’s Compact Geared Extruder.

I like the small, modular design, and particularly like how he’s approached the transfer of torque in the main gear.  This requires three set (grub) screws to go the radius of the gear, and I didn’t have any lying around.  A few minutes with some M3 bolts and a hacksaw though yielded sufficiently long and stable screws.

Printing

First Watertight MiniMug

Printing

Pulleys

After several attempts at printing a usable pulley I threw a question into the forum to see if there was anything I was missing.

Either the pulley spurs are too wide (top right image in the gallery below), and so the belt teeth rides up on them, or the spurs are unstable and a mess (row 2, left), plus the spindle doesn’t fit on the motor.

The suggestions and information from the forum was good – my Skeinforge settings needed more calibrating (note: use 100mm of feedstock for measuring the throughput, not 10mm), and nophead told me that the motor spindles are expected to be reamed.

So just as I start producing what looks like usable results, the hot end blocked and I broke the Z axis coupling.  So I loaded up the 0.35mm hot end to see if I can get better results with that.  Having a smaller nozzle brings it’s own problems: you have to be more precise in your positioning (particularly with the Z axis), and the cohesion between layers seems to be trickier to maintain.  After some fiddling in Skeinforge I was producing reasonable quality prints (row 2,right), and my test pulley prints started to fit the belt much easier (row 3, left, this is Greg’s modified pulley).  However the layer quality was still pretty messy (row 3, right).  More playing in Skeinforge started to yield better results (row 4), by also reducing the speed in repsnapper when the print reached the spurs (even though feed and flow was already set to 15mm/s).

Printing Skeinforge

Skeinforge 40

After a good few evenings of wrangling with the latest version of Skeinforge 40 (11.02.23) I have finally got it working. Here are a few details in case others find themselves having problems too.

After upgrading, the extruder seemed not to move during a print.

The core problem boiled down to a change in how version 40 calculates feedstock throughput, the solution being to modify the e_steps_per_mm setting in the firmware (in my case from 22 to 539), and tweak the skeinforge settings.  The e_steps_per_mm calculation is micro steps per rev * gear ratio / ( pinch wheel diameter * 3.14), and in my case 3200 * (39/11) / (6.7 * 3.14) = 539.  The forum actually had a lengthy thread about this (which I annoyingly overlooked at first), but the suggestions there didn’t seem to solve my problem.

After much searching, and many test attempts, I finally delved into the gcode itself.  There I found that the start gcode of the preface module had a command which set the e_steps_per_mm value back to 22! (gcode: “M92 E22”) This gcode file was originally part of the Skeinforge pack that Prusa bundled as part of his introduction. I tried setting the value to E539, to match the firmware, but this seemed to send the extruder crazy, so I left it at E22 and added a command at the end to set it to E539.  The complete gcode segment is:

M140 S60 ; bed temp
M92 E22 ; custom code to set extruder steps!!
G92 X0 Y0 Z0  E0.0
G1 Z2.0 F150.0
G1 X-250.0 F2100.0
G1 X-249.0 F300.0
G1 X-251.0 F100.0
G92 X10.0
G1 Y-250.0 F2100.0
G1 Y-249.0 F300.0
G1 Y-251.0 F300.0
G92 Y0.0
G1 Y70.0 F2100.0
G1 Z-250.0 F150.0
G1 Z-249.0 F50.0
G1 Z-251.0 F50.0
G1 Y75.0 E100.0  F1000.0
G1 Y100.0 E130.0  F1000.0
G92 Z0.2
G92 E0.0
M92 E554 ; custom code to set extruder steps!!

Another gotcha was that the movement at the start of the print, to set the initial position of the print head, was very slow.  By the time the print started enough PLA had dribbled out to affect the quality.  This was caused by the “Maximum Initial Feed Rate” setting in the limit module being set to 1. I’m not sure if I set this or it was defaulted to it, but setting it to 75 sped things up.

The bright side of all this fiddling is that I now have a much better understanding of Skeinforge and gcodes, and the 20mm calibration print I fired off tonight is the best one so far!

Below are the Skeinforge settings that got the result. There is still some fine tuning to go, but perhaps they are useful for someone. I extract them to html using a groovy script at the moment, but I hope to develop something useful so people can easily record, share and compare skeinforge settings.


Toolchain

Firmware
tonokip via prusasw bundle
Repsnapper
Version 04.09.11
Skeinforge
Version 11.02.23
Layer Thickness (mm): 0.4
Perimeter Width over Thickness (ratio): 1.35
Infill Solidity (ratio): 1.0
Feed Rate (mm/s): 30.0
Flow Rate Setting (float): 30.0
Object Next Layers Temperature (Celcius): 200.0
More Skeinforge Settings
bottom
Activate Bottom True
Additional Height over Layer Thickness (ratio): 0.5
Altitude (mm): 0.0
SVG Viewer: webbrowser
carve
Add Layer Template to SVG True
Extra Decimal Places (float): 2.0
Import Coarseness (ratio): 1.0
Infill in Direction of Bridge True
Layer Thickness (mm): 0.4
Layers From (index): 0
Layers To (index): 912345678
Correct Mesh True
Unproven Mesh False
Perimeter Width over Thickness (ratio): 1.35
SVG Viewer: webbrowser
chamber
Activate Chamber: False
Bed Temperature (Celcius): 60.0
Chamber Temperature (Celcius): 30.0
Holding Force (bar): 0.0
clip
Activate Clip True
Clip Over Perimeter Width (ratio): 0.15
Maximum Connection Distance Over Perimeter Width (ratio): 10.0
comb
Activate Comb False
comment
cool
Activate Cool False
Bridge Cool (Celcius): 1.0
Orbit True
Slow Down False
Maximum Cool (Celcius): 2.0
Minimum Layer Time (seconds): 60.0
Minimum Orbital Radius (millimeters): 10.0
Name of Cool End File: cool_end.gcode
Name of Cool Start File: cool_start.gcode
Turn Fan On at Beginning True
Turn Fan Off at Ending True
dimension
Activate Dimension True
Absolute Extrusion Distance True
Relative Extrusion Distance False
Extruder Retraction Speed (mm/s): 10.0
Filament Diameter (mm): 2.8
Filament Packing Density (ratio): 0.95
Retraction Distance (millimeters): 1.0
Restart Extra Distance (millimeters): 0.0
export
Activate Export True
Add Export Suffix True
Do Not Delete Comments False
Delete Crafting Comments False
Delete All Comments True
Do Not Change Output True
binary_16_byte False
gcode_step False
gcode_time_segment False
gcode_small False
File Extension: gcode
Name of Replace File: replace.csv
Save Penultimate Gcode False
fill
Activate Fill: True
Diaphragm Period (layers): 100
Diaphragm Thickness (layers): 0
Extra Shells on Alternating Solid Layer (layers): 2
Extra Shells on Base (layers): 1
Extra Shells on Sparse Layer (layers): 1
Grid Circle Separation over Perimeter Width (ratio): 0.2
Grid Extra Overlap (ratio): 0.1
Grid Junction Separation Band Height (layers): 10
Grid Junction Separation over Octogon Radius At End (ratio): 0.0
Grid Junction Separation over Octogon Radius At Middle (ratio): 0.0
Infill Begin Rotation (degrees): 45.0
Infill Begin Rotation Repeat (layers): 1
Infill Odd Layer Extra Rotation (degrees): 90.0
Grid Circular False
Grid Hexagonal False
Grid Rectangular False
Line True
Infill Perimeter Overlap (ratio): 0.15
Infill Solidity (ratio): 1.0
Infill Width over Thickness (ratio): 1.5
Solid Surface Thickness (layers): 3
Lower Left True
Nearest False
Infill > Loops > Perimeter False
Infill > Perimeter > Loops False
Loops > Infill > Perimeter False
Loops > Perimeter > Infill True
Perimeter > Infill > Loops False
Perimeter > Loops > Infill False
fillet
Activate Fillet True
Arc Point False
Arc Radius False
Arc Segment False
Bevel True
Corner Feed Rate over Operating Feed Rate (ratio): 1.0
Fillet Radius over Perimeter Width (ratio): 0.35
Reversal Slowdown Distance over Perimeter Width (ratio): 0.5
Use Intermediate Feed Rate in Corners True
home
Activate Home False
Name of Homing File: homing.gcode
hop
Activate Hop False
Hop Over Layer Thickness (ratio): 1.0
Minimum Hop Angle (degrees): 30.0
inset
Add Custom Code for Temperature Reading True
Bridge Width Multiplier (ratio): 1.0
Ascending Area True
Descending Area False
Overlap Removal Width over Perimeter Width (ratio): 0.6
Turn Extruder Heater Off at Shut Down True
interpret
Activate Interpret False
Print Interpretion False
Text Program: webbrowser
jitter
Activate Jitter True
Jitter Over Perimeter Width (ratio): 2.0
lash
Activate Lash False
X Backlash (mm): 0.2
Y Backlash (mm): 0.3
limit
Activate Limit True
Maximum Initial Feed Rate (mm/s): 75.0
Maximum Z Feed Rate (mm/s): 1.0
multiply
Activate Multiply: True
Center X (mm): 100.0
Center Y (mm): 100.0
Number of Columns (integer): 1
Number of Rows (integer): 1
Separation over Perimeter Width (ratio): 15.0
oozebane
Activate Oozebane False
After Startup Distance (millimeters): 1.2
Early Shutdown Distance (millimeters): 1.2
Early Startup Distance Constant (millimeters): 20.0
Early Startup Maximum Distance (millimeters): 1.2
First Early Startup Distance (millimeters): 25.0
Minimum Distance for Early Startup (millimeters): 0.0
Minimum Distance for Early Shutdown (millimeters): 0.0
Slowdown Startup Steps (positive integer): 3
polyfile
Execute File True
preface
Name of End File: end.gcode
Name of Start File: startMendel05l04PLA.gcode
Set Positioning to Absolute True
Set Units to Millimeters True
Start at Home False
Turn Extruder Off at Shut Down False
Turn Extruder Off at Start Up False
raft
Activate Raft False
Add Raft, Elevate Nozzle, Orbit: False
Base Feed Rate Multiplier (ratio): 1.0
Base Flow Rate Multiplier (ratio): 1.0
Base Infill Density (ratio): 0.5
Base Layer Thickness over Layer Thickness: 2.0
Base Layers (integer): 1
Base Nozzle Lift over Base Layer Thickness (ratio): 0.4
Initial Circling: False
Infill Overhang over Extrusion Width (ratio): 0.05
Interface Feed Rate Multiplier (ratio): 1.0
Interface Flow Rate Multiplier (ratio): 1.0
Interface Infill Density (ratio): 0.5
Interface Layer Thickness over Layer Thickness: 1.0
Interface Layers (integer): 2
Interface Nozzle Lift over Interface Layer Thickness (ratio): 0.45
Name of Support End File: support_end.gcode
Name of Support Start File: support_start.gcode
Object First Layer Feed Rate Infill Multiplier (ratio): 0.4
Object First Layer Feed Rate Perimeter Multiplier (ratio): 0.4
Object First Layer Flow Rate Infill Multiplier (ratio): 0.4
Object First Layer Flow Rate Perimeter Multiplier (ratio): 0.4
Operating Nozzle Lift over Layer Thickness (ratio): 0.5
Raft Additional Margin over Length (%): 1.0
Raft Margin (mm): 3.0
Support Cross Hatch False
Support Flow Rate over Operating Flow Rate (ratio): 1.0
Support Gap over Perimeter Extrusion Width (ratio): 1.0
None True
Empty Layers Only False
Everywhere False
Exterior Only False
Support Minimum Angle (degrees): 60.0
scale
Activate Scale: False
XY Plane Scale (ratio): 1.01
Z Axis Scale (ratio): 1.0
SVG Viewer: webbrowser
skeinforge
analyze False
craft False
help False
meta False
profile True
skeinforge_analyze
comment False
interpret False
skeiniso False
skeinlayer True
statistic False
vectorwrite False
skeinforge_craft
bottom False
carve False
chamber False
chop False
cleave False
clip False
coil False
comb False
cool False
dimension False
drill False
export False
feed False
fill False
fillet False
flow False
home False
hop False
inset False
jitter False
lash False
lift False
limit False
mill False
multiply False
oozebane False
outset False
preface False
raft False
scale False
skirt False
speed False
splodge False
stretch False
temperature True
tower False
unpause False
whittle False
widen False
wipe False
skeinforge_help
skeiniso
Activate Skeiniso False
Animation Line Quickening (ratio): 1.0
Animation Slide Show Rate (layers/second): 2.0
Axis Rulings True
Band Height (layers): 5
Bottom Band Brightness (ratio): 0.7
Bottom Layer Brightness (ratio): 1.0
From the Bottom False
From the Top True
Draw Arrows False
Go Around Extruder Off Travel False
Layer (index): 0
Layer Extra Span (integer): 912345678
Line (index): 0
Display Line True
View Move False
View Rotate False
Number of Fill Bottom Layers (integer): 1
Number of Fill Top Layers (integer): 1
Scale (pixels per millimeter): 15.0
Screen Horizontal Inset (pixels): 100
Screen Vertical Inset (pixels): 220
Show Gcode True
Viewpoint Latitude (degrees): 15.0
Viewpoint Longitude (degrees): 210.0
Width of Axis Negative Side (pixels): 2
Width of Axis Positive Side (pixels): 6
Width of Fill Bottom Thread (pixels): 2
Width of Fill Top Thread (pixels): 2
Width of Infill Thread (pixels): 1
Width of Loop Thread (pixels): 2
Width of Perimeter Inside Thread (pixels): 8
Width of Perimeter Outside Thread (pixels): 8
Width of Raft Thread (pixels): 1
Width of Selection Thread (pixels): 6
Width of Travel Thread (pixels): 0
skeinlayer
Activate Skeinlayer True
Animation Line Quickening (ratio): 1.0
Animation Slide Show Rate (layers/second): 2.0
Draw Arrows True
Go Around Extruder Off Travel False
Layer (index): 0
Layer Extra Span (integer): 0
Line (index): 0
Display Line True
View Move False
Scale (pixels per millimeter): 15.0
Screen Horizontal Inset (pixels): 100
Screen Vertical Inset (pixels): 220
Show Gcode True
Show Position True
Width of Extrusion Thread (pixels): 3
Width of Selection Thread (pixels): 6
Width of Travel Thread (pixels): 1
skirt
Activate Skirt: False
Gap over Perimeter Width (ratio): 1.0
Layers To (index): 1
speed
Activate Speed: True
Add Flow Rate: True
Bridge Feed Rate Multiplier (ratio): 1.0
Bridge Flow Rate Multiplier (ratio): 1.0
Duty Cyle at Beginning (portion): 1.0
Duty Cyle at Ending (portion): 0.0
Feed Rate (mm/s): 30.0
Flow Rate Setting (float): 30.0
Orbital Feed Rate over Operating Feed Rate (ratio): 0.5
Perimeter Feed Rate over Operating Feed Rate (ratio): 0.6
Perimeter Flow Rate over Operating Flow Rate (ratio): 0.6
Travel Feed Rate (mm/s): 30.0
splodge
Activate Splodge False
Initial Lift over Extra Thickness (ratio): 1.0
Initial Splodge Feed Rate (mm/s): 1.0
Initial Splodge Quantity Length (millimeters): 30.0
Operating Lift over Extra Thickness (ratio): 1.0
Operating Splodge Feed Rate (mm/s): 1.0
Operating Splodge Quantity Length (millimeters): 1.0
statistic
Machine Time ($/hour): 1.0
Material ($/kg): 10.0
Density (kg/m3): 930.0
Extrusion Diameter over Thickness (ratio): 1.25
Print Statistics True
Save Statistics False
stretch
Activate Stretch True
Cross Limit Distance Over Perimeter Width (ratio): 5.0
Loop Stretch Over Perimeter Width (ratio): 0.11
Path Stretch Over Perimeter Width (ratio): 0.0
Perimeter Inside Stretch Over Perimeter Width (ratio): 0.32
Perimeter Outside Stretch Over Perimeter Width (ratio): 0.1
Stretch From Distance Over Perimeter Width (ratio): 2.0
temperature
Activate Temperature: True
Cooling Rate (Celcius/second): 3.0
Heating Rate (Celcius/second): 10.0
Base Temperature (Celcius): 200.0
Interface Temperature (Celcius): 200.0
Object First Layer Infill Temperature (Celcius): 200.0
Object First Layer Perimeter Temperature (Celcius): 200.0
Object Next Layers Temperature (Celcius): 200.0
Support Layers Temperature (Celcius): 200.0
Supported Layers Temperature (Celcius): 200.0
tower
Activate Tower False
Extruder Possible Collision Cone Angle (degrees): 60.0
Maximum Tower Height (layers): 5
Tower Start Layer (integer): 1
unpause
Activate Unpause False
Delay (milliseconds): 28.0
Maximum Speed (ratio): 1.3
vectorwrite
Add Loops True
Add Paths True
Add Perimeters True
Layers From (index): 0
Layers To (index): 912345678
SVG Viewer: webbrowser
widen
Activate Widen: False
wipe
Activate Wipe False
Location Arrival X (mm): -70.0
Location Arrival Y (mm): -50.0
Location Arrival Z (mm): 50.0
Location Departure X (mm): -70.0
Location Departure Y (mm): -40.0
Location Departure Z (mm): 50.0
Location Wipe X (mm): -70.0
Location Wipe Y (mm): -70.0
Location Wipe Z (mm): 50.0
Wipe Period (layers): 3

 

Printing

Cube Gears


An afternoon wrestling with Skeinforge and a replacement hot end yielded only frustration. But after a break things came together nicely and I managed to print an entire set of Emmet’s Cube Gears!


Toolchain

Firmware
tonokip via prusasw bundle
Repsnapper
Version 04.09.11
Notes speed multiplier: 1.25
Skeinforge
Version 10.08.19
Layer Thickness (mm): 0.4
Perimeter Width over Thickness (ratio): 1.35
Infill Solidity (ratio): 1.0
Feed Rate (mm/s): 40.0
Flow Rate Setting (float): 40.0
Object Next Layers Temperature (Celcius): 190.0
More Skeinforge Settings
bottom
Activate Bottom True
Additional Height over Layer Thickness (ratio): 0.5
Altitude (mm): 0.0
SVG Viewer: webbrowser
carve
Add Layer Template to SVG True
Bridge Thickness Multiplier (ratio): 1.0
Extra Decimal Places (integer): 1
Import Coarseness (ratio): 1.0
Infill in Direction of Bridges True
Layer Thickness (mm): 0.4
Layers From (index): 0
Layers To (index): 912345678
Correct Mesh True
Unproven Mesh False
Perimeter Width over Thickness (ratio): 1.35
SVG Viewer: webbrowser
chamber
Activate Chamber: False
Bed Temperature (Celcius): 60.0
Chamber Temperature (Celcius): 30.0
Holding Force (bar): 0.0
chop
Add Extra Top Layer if Necessary True
Add Layer Template to SVG True
Extra Decimal Places (integer): 1
Import Coarseness (ratio): 1.0
Layer Thickness (mm): 0.4
Layers From (index): 0
Layers To (index): 912345678
Correct Mesh True
Unproven Mesh False
Perimeter Width (mm): 2.0
SVG Viewer: webbrowser
clip
Activate Clip True
Clip Over Perimeter Width (ratio): 0.5
Maximum Connection Distance Over Perimeter Width (ratio): 10.0
comb
Activate Comb False
comment
cool
Activate Cool True
Orbit False
Slow Down True
Maximum Cool (Celcius): 9.5
Minimum Layer Time (seconds): 10.0
Minimum Orbital Radius (millimeters): 10.0
Turn Fan On at Beginning False
Turn Fan Off at Ending False
dimension
Activate Dimension True
Absolute Extrusion Distance True
Relative Extrusion Distance False
Extruder Retraction Speed (mm/s): 100.0
Retraction Distance (millimeters): 10.0
Restart Extra Distance (millimeters): 3.0
export
Activate Export True
Delete Comments True
Do Not Change Output True
binary_16_byte False
gcode_step False
gcode_small False
File Extension: gcode
Save Penultimate Gcode False
fill
Activate Fill: True
Diaphragm Period (layers): 100
Diaphragm Thickness (layers): 0
Extra Shells on Alternating Solid Layer (layers): 1
Extra Shells on Base (layers): 1
Extra Shells on Sparse Layer (layers): 1
Grid Extra Overlap (ratio): 0.1
Grid Junction Separation Band Height (layers): 10
Grid Junction Separation over Octogon Radius At End (ratio): 0.0
Grid Junction Separation over Octogon Radius At Middle (ratio): 0.0
Infill Begin Rotation (degrees): 45.0
Infill Begin Rotation Repeat (layers): 1
Infill Interior Density over Exterior Density (ratio): 0.9
Infill Odd Layer Extra Rotation (degrees): 90.0
Grid Hexagonal False
Grid Rectangular False
Line True
Infill Perimeter Overlap (ratio): 0.15
Infill Solidity (ratio): 1.0
Infill Width over Thickness (ratio): 1.5
Solid Surface Thickness (layers): 3
Infill > Loops > Perimeter False
Infill > Perimeter > Loops False
Loops > Infill > Perimeter False
Loops > Perimeter > Infill False
Perimeter > Infill > Loops False
Perimeter > Loops > Infill True
fillet
Activate Fillet False
Arc Point False
Arc Radius False
Arc Segment False
Bevel True
Corner Feed Rate over Operating Feed Rate (ratio): 1.0
Fillet Radius over Perimeter Width (ratio): 0.35
Reversal Slowdown Distance over Perimeter Width (ratio): 0.5
Use Intermediate Feed Rate in Corners True
home
Activate Home True
Name of Homing File: homing.gcode
hop
Activate Hop False
Hop Over Layer Thickness (ratio): 1.0
Minimum Hop Angle (degrees): 30.0
inset
Add Custom Code for Temperature Reading True
Bridge Width Multiplier (ratio): 1.0
Ascending Area True
Descending Area False
Overlap Removal Width over Perimeter Width (ratio): 0.6
Turn Extruder Heater Off at Shut Down True
interpret
Activate Interpret False
Print Interpretion False
Text Program: webbrowser
jitter
Activate Jitter True
Jitter Over Perimeter Width (ratio): 3.0
lash
Activate Lash False
X Backlash (mm): 0.2
Y Backlash (mm): 0.3
limit
Activate Limit False
Maximum Initial Feed Rate (mm/s): 1.0
multiply
Activate Multiply: True
Center X (mm): 100.0
Center Y (mm): 100.0
Number of Columns (integer): 1
Number of Rows (integer): 1
Separation over Perimeter Width (ratio): 7.0
oozebane
Activate Oozebane False
After Startup Distance (millimeters): 0.0
Early Shutdown Distance (millimeters): 1.2
Early Startup Distance Constant (millimeters): 20.0
Early Startup Maximum Distance (millimeters): 1.2
First Early Startup Distance (millimeters): 25.0
Minimum Distance for Early Startup (millimeters): 0.0
Minimum Distance for Early Shutdown (millimeters): 10.0
Slowdown Startup Steps (positive integer): 3
polyfile
Execute File True
preface
Name of End File: end.gcode
Name of Start File: startMendel05l04PLA.gcode
Set Positioning to Absolute True
Set Units to Millimeters True
Start at Home False
Turn Extruder Off at Shut Down True
Turn Extruder Off at Start Up False
raft
Activate Raft True
Add Raft, Elevate Nozzle, Orbit and Set Altitude: True
Base Feed Rate Multiplier (ratio): 1.0
Base Flow Rate Multiplier (ratio): 1.0
Base Infill Density (ratio): 0.5
Base Layer Thickness over Layer Thickness: 2.0
Base Layers (integer): 0
Base Nozzle Lift over Base Layer Thickness (ratio): 0.4
Bottom Altitude: 0.0
Infill Overhang over Extrusion Width (ratio): 0.05
Interface Feed Rate Multiplier (ratio): 1.0
Interface Flow Rate Multiplier (ratio): 1.0
Interface Infill Density (ratio): 0.5
Interface Layer Thickness over Layer Thickness: 1.0
Interface Layers (integer): 0
Interface Nozzle Lift over Interface Layer Thickness (ratio): 0.45
Object First Layer Feed Rate Infill Multiplier (ratio): 0.5
Object First Layer Feed Rate Perimeter Multiplier (ratio): 0.5
Object First Layer Flow Rate Multiplier (ratio): 0.71
Operating Nozzle Lift over Layer Thickness (ratio): 0.5
Raft Additional Margin over Length (%): 1.0
Raft Margin (mm): 3.0
Support Cross Hatch False
Support Flow Rate over Operating Flow Rate (ratio): 1.0
Support Gap over Perimeter Extrusion Width (ratio): 1.0
None True
Empty Layers Only False
Everywhere False
Exterior Only False
Support Minimum Angle (degrees): 60.0
scale
Activate Scale: False
XY Plane Scale (ratio): 1.01
Z Axis Scale (ratio): 1.0
SVG Viewer: webbrowser
skeinforge
analyze False
craft True
help False
meta False
profile False
skeinforge_craft
bottom False
carve False
chamber False
chop False
cleave False
clip False
coil False
comb False
cool False
dimension True
drill False
export False
feed False
fill False
fillet False
flow False
home False
hop False
inset False
jitter False
lash False
lift False
limit False
mill False
multiply False
oozebane False
outset False
preface False
raft False
scale False
skirt False
speed False
splodge False
stretch False
temperature False
tower False
unpause False
whittle False
widen False
wipe False
skeinforge_help
skeiniso
Activate Skeiniso True
Animation Line Quickening (ratio): 1.0
Animation Slide Show Rate (layers/second): 2.0
Axis Rulings True
Band Height (layers): 5
Bottom Band Brightness (ratio): 0.7
Bottom Layer Brightness (ratio): 1.0
From the Bottom False
From the Top True
Draw Arrows False
Go Around Extruder Off Travel False
Layer (index): 0
Layer Extra Span (integer): 912345678
Line (index): 0
Display Line True
View Move False
View Rotate False
Number of Fill Bottom Layers (integer): 1
Number of Fill Top Layers (integer): 1
Scale (pixels per millimeter): 15.0
Screen Horizontal Inset (pixels): 100
Screen Vertical Inset (pixels): 220
Show Gcode True
Viewpoint Latitude (degrees): 15.0
Viewpoint Longitude (degrees): 210.0
Width of Axis Negative Side (pixels): 2
Width of Axis Positive Side (pixels): 6
Width of Fill Bottom Thread (pixels): 2
Width of Fill Top Thread (pixels): 2
Width of Infill Thread (pixels): 1
Width of Loop Thread (pixels): 2
Width of Perimeter Inside Thread (pixels): 8
Width of Perimeter Outside Thread (pixels): 8
Width of Raft Thread (pixels): 1
Width of Selection Thread (pixels): 6
Width of Travel Thread (pixels): 0
skeinlayer
Activate Skeinlayer True
Animation Line Quickening (ratio): 1.0
Animation Slide Show Rate (layers/second): 2.0
Draw Arrows True
Go Around Extruder Off Travel False
Layer (index): 0
Layer Extra Span (integer): 0
Line (index): 0
Display Line True
View Move False
Scale (pixels per millimeter): 15.0
Screen Horizontal Inset (pixels): 100
Screen Vertical Inset (pixels): 220
Show Gcode True
Show Position True
Width of Extrusion Thread (pixels): 3
Width of Selection Thread (pixels): 6
Width of Travel Thread (pixels): 1
skirt
Activate Skirt: False
Gap over Perimeter Width (ratio): 1.0
Layers To (index): 1
speed
Activate Speed: True
Add Flow Rate: True
Bridge Feed Rate Multiplier (ratio): 1.0
Bridge Flow Rate Multiplier (ratio): 1.0
Duty Cyle at Beginning (portion): 1.0
Duty Cyle at Ending (portion): 0.0
Feed Rate (mm/s): 40.0
Flow Rate Setting (float): 40.0
Maximum Z Feed Rate (mm/s): 3.5
Orbital Feed Rate over Operating Feed Rate (ratio): 0.9
Perimeter Feed Rate over Operating Feed Rate (ratio): 0.5
Perimeter Flow Rate over Operating Flow Rate (ratio): 0.5
Travel Feed Rate (mm/s): 75.0
splodge
Activate Splodge False
Initial Lift over Extra Thickness (ratio): 1.0
Initial Splodge Feed Rate (mm/s): 1.0
Initial Splodge Quantity Length (millimeters): 30.0
Operating Lift over Extra Thickness (ratio): 1.0
Operating Splodge Feed Rate (mm/s): 1.0
Operating Splodge Quantity Length (millimeters): 1.0
statistic
Machine Time ($/hour): 1.0
Material ($/kg): 10.0
Density (kg/m3): 930.0
Extrusion Diameter over Thickness (ratio): 1.25
Print Statistics True
Save Statistics False
stretch
Activate Stretch False
Cross Limit Distance Over Perimeter Width (ratio): 5.0
Loop Stretch Over Perimeter Width (ratio): 0.11
Path Stretch Over Perimeter Width (ratio): 0.0
Perimeter Inside Stretch Over Perimeter Width (ratio): 0.32
Perimeter Outside Stretch Over Perimeter Width (ratio): 0.1
Stretch From Distance Over Perimeter Width (ratio): 2.0
temperature
Activate Temperature: True
Initial Circling: False
Cooling Rate (Celcius/second): 3.0
Heating Rate (Celcius/second): 10.0
Chamber Temperature (Celcius): 25.0
Base Temperature (Celcius): 190.0
Interface Temperature (Celcius): 190.0
Object First Layer Infill Temperature (Celcius): 195.0
Object First Layer Perimeter Temperature (Celcius): 195.0
Object Next Layers Temperature (Celcius): 190.0
Support Layers Temperature (Celcius): 190.0
Supported Layers Temperature (Celcius): 190.0
tower
Activate Tower False
Extruder Possible Collision Cone Angle (degrees): 60.0
Maximum Tower Height (layers): 5
Tower Start Layer (integer): 1
unpause
Activate Unpause False
Delay (milliseconds): 28.0
Maximum Speed (ratio): 1.3
vectorwrite
Activate Vectorwrite False
Layers From (index): 0
Layers To (index): 912345678
widen
Activate Widen: False
wipe
Activate Wipe False
Location Arrival X (mm): -70.0
Location Arrival Y (mm): -50.0
Location Arrival Z (mm): 50.0
Location Departure X (mm): -70.0
Location Departure Y (mm): -40.0
Location Departure Z (mm): 50.0
Location Wipe X (mm): -70.0
Location Wipe Y (mm): -70.0
Location Wipe Z (mm): 50.0
Wipe Period (layers): 3
Printing

Largest print so far

Got to print the Accessible Wade’s Extruder by GregFrost at the weekend.  I thought I would be able to set it off and go and do some other work, but couldn’t stop watching over it and being a bit nervous due to it’s size and (relative) complexity.

Apart from the bridge over the bearing holders not holding up too well, and looking a bit scruffy due to some discoloured ooze, it came out quite well and I think it will be usable.

And then my hot end broke – as predicted by Robert Morrison a few days ago.  Time to build the replacement, and order the parts for the new and improved version.