Index

„„         A

„„         B

Acrylonitrile butadiene styrene (ABS) juice, 219 acetone vapor, 221 action process, 220 Kapton tape, 222 paint brush, 222 pipe cement, 351 plumbing cement, 354 preparation, 219 razor tool, 221 removed surface, 220 Adhesion problems, 482 Adjustment tasks, 3D printer, 312 filament drive pulley cleaning, 318 disconnect stepper motor, 319 reassemble extruder and load filament, 322 remove debris, 321 remove stepper motor, 321 removing extruder fan, 320 unload filament, 319 frequency, 312 nozzle cleaning acetone, 325 ESD-safe tweezers, 324 j-head nozzle, 322–323 soft wire brush, 324 print bed leveling procedure, 313 MarkerBot Replicator 1, 314–315 startup screens, 314 Z-height adjuster, 317 Airwolf, 59 All-metal hot ends, 75

Bar clamps, 342 Belt-driven mechanisms, 138 Belts, 343 clamps, 342 closed-loop belts, 310 loose belts, 309 Bench testing, 118 Blender CAD application, 10 Blue painter’s tape advantage, 209 cost analysis, 210 cut, excess tape, 212 gap smoothening, 212 vs.green and yellow tape, 209 manufacturer’s logo, 210 masking tape, 208 outer edge alignment, 211–212 overhang, 210 removing parts, 209 in rows, 210 strip replacement, 213 surface distortion, discoloration, 213 Z-height, 213 Build plate, 343

„„         C Canned air, 330 Ceramic screwdriver, 93 Clogged extruder, 257 Cold pull method, 256 Complete printrbot simple kit, 104 Component kits, 106

489

■ index

Computer-aided design (CAD), 8 Computer-aided manufacturing (CAM), 2 Consumer grade Airwolf, 59 commodity components, 58 Deezmaker, 59 MakerGear, 59 Maxbots, 59 Printrbot, 59–60 SeeMeCNC, 59–60 Corrective maintenance bearings and bushings, 364–365 belt tensioners, 363 broken ABS parts, 353 broken/worn plastic parts bolt length, 352 threaded rod frames, 351 clogged nozzle in acetone, 350 clearing procedure, 346 extrusion failure, 346 in flame, 346 plastic debris removal, 347 reheat, 349 replacement nozzles, 350 tools, 346 wire brush cleaning, 350 closed belts X-axis belt replacement, 358 Y-axis belt replacement, 359 extruder gears, 355 filters, 366 firmware, 344 open belts, 357 smooth rods, 365

„„         D Deezmaker, 59 Delta Micro Factory Corporation, 56 Digital caliper, 88 Drill bits, 96

„„         E Electromagnetic interference (EMI), 269 Electronics board, 343 Electrostatic discharge (ESD), 268 Endstop holders, 342–343 Endstop setting X-axis Prusa.i2, 176 Prusa i3, 177–178

490

Y-axis Prusa i2, 179 Prusa i3, 179–180 Z-axis, 181 Prusa i2, 182 Prusa i3, 183 Prusa i3 auto bed leveling, 184 Z-height adjusters, 181 Enhancement, 3D printers calibration check, 381 farkles beautification, 370 definition, 370 LED light, 371 feature upgrades LCD panel, 376 Z-height adjuster, 378 generic upgrades adjustable feet, 383–384 fans, 383 lighting, 382, 384 goals and expectations, 381 printer-specific upgrades (see Printer-specific upgrades) quality filament management, 372 heated print bed insulation, 374 search terms, 380 Exhaust fabric, 374 Exhaust header wrap, 374 Extruder, 193 extruder body, 307 filament drive gear, 306 filament failures, 256 gears inspection, 308, 342 idler bearing, 309 idler door, 307 idler mount, 342 mechanism, 255 nozzle obstructions, 256 printer calibration filament 0mm, 195 filament 100mm and 120mm, 195 filament loaded, 194 overrun, 198 process, 194 Repetier-Host filament extrusion, 196 underrun, 197, 199 stepper motor, 306 wire fatigue, 309 Electric static discharge (ESD), 88 Extrusion failure, 346, 483

■ Index

„„         F Filament environmental factors, 254 filter/cleaner designs, 253–254 quality, 252 spool holder, 252 Firmware, 293. See also Marlin firmware FrogTape, 209 Fume extraction filters, 366 Fume extractor, 94 Fused deposition modeling (FDM), 5

„„         G Gate hinge, 474 G-code, 15

„„         H Hardware problems adhesion, 257 big acrylic box, 262 cut adhesive side, 261 definition, 257 drafts, 259–260 folding tape, 261 print bed adjustments, 258 print surface, 258 removable blue painter, 261–262 skirt, 260 thermal enclosure, 262 wooden box, 262 axes adjustments, 263 lack maintenance, 265 obstructions, 263 print failure, 264 electrical component, 265 electronics board, 268 endstop holders, 268 LCD panel, 269 SD card reader, 268 stepper motors, 266 switches, 268 wiring, 267 extruder filament failures, 256 mechanism, 255 nozzle obstructions, 256 retraction, 255 filament environmental factors, 254 filter/cleaner designs, 253–254

quality, 252 spool holder, 252 solutions vs. magical cures, 246 troubleshooting baseline definition, 247 causes, 249 observations and recording, 248–249 strategy implementations, 250 white tape, 246 Header/manifold, 374 Heat gun, 97 Home Zillions, 363

„„         I, J Inspection tasks, 3D printer, 301 axes, 305 belts closed-loop belts, 310 loose belts, 309 extruder extruder body, 307 filament drive gear, 306 gears inspection, 308 idler bearing, 309 idler door, 307 stepper motor, 306 wire fatigue, 309 filament, 306 frame (chasis), 303 broken parts, 305 check alignment, 304 tighten bolts, 303 frequency, 302 print surface, 311 wiring, 310

„„         K Kapton tape, 102 ABS printing, 213, 219 action process, 215–217 features, 213 instructions, 215 print bed, 218 preparation, 208 problematic dry application, 218 removing parts, 214 roll, 213–214 wider widths, 215 Z-height, 219 Kit-based printers, 310

491

■ index

„„         L Liquid-crystal display (LCD) panel Marlin firmware, 377 Printrbot, 377 Printrbot Simple, 385, 388 Prusa i3, 377, 400 Prusa Mendel i2, 376, 393 lcd_status_screen() method, 154 Lead screw–driven axis calculations. See Threaded rod–driven mechanism Lulzbot, 56

„„         M MakerBot Desktop software, 478 MakerBot Digitizer, 478 MakerBot Industries, 55 MakerBot Replicator 2/2x, 363. See also Y-axis belt MakerBot Replicator Desktop, 56 MakerFarm, 68 MakerGear, 59 MakerWare, 18 Marlin firmware Arduino board, 132 Arduino IDE, 131 Arduino Mega 2560 microcontroller, 130 belt-driven mechanisms, 135 blink, 131 compiling and uploading, 151 configuration author and version, 143 axes movement, 147 baud rate, 143 EEPROM, 149 electronics board, 143 endstops settings, 146 LCD panel, 150 temperature sensors, 144–145 custom menu items, 153 downloading, 133 gear-driven axes, 136 hardware feature, 130 RepRap calculator 10mm tall test cube measurement, 140–141 acceleration calculation, 141 belt-driven axis calculation, 138 optimal layer height calculation, 139–140 threaded rod–driven axis calculation, 138 serial port menu option, 132–133 stepper motor, 136 threaded rod-driven mechanisms, 136 welcome message, 154

492

Maxbots, 59 Mechanical/electrical problems, 486 Metric drill bits, 96 Mk7 Stepstruder, 341 Multimeter, 92

„„         N NextDayRepRap, 68 NorCal-RepRap, 68 Nozzle, 343

„„         O O2 Hurricane, 330–331 Objects creation OpenSCAD (see OpenSCAD) Thingiverse, 429 thread spool (see Thread spool creation) modification MakerBot Replicator 2, 440 post-print finishing (see Post-print finishing, objects) OctoPrint software, 164 OpenSCAD, 429 applications, 430 complex object, 434 coordinate key, 430 cube() statement, 431 cylinder() statement, 432–433, 435 difference() statement, 432 modification, 440 PCB offset, 433–434 rotate() statement, 435 translate() statement, 431 union() statement, 435 Open source software, 8

„„         P, Q Parts-only kit, 105 Post-print finishing, objects ABS acetone vapor bath advantages, 448 basket lining, Kapton tape, 450 cleanup, 452 process, 451 surface smoothening, 449 vessel, 448 key preparation cleanup, 443 sanding, 445 surface treatments, 446 multipart assembling, 452 painting, 446

■ Index

Preventive maintenance cleaning build area, 331 cool gadget, 330 dirt, 328 electronics, 329 frame and purpose, 328–329 thread and smooth rods, 331 tracks and v-channels, 335 lubrication grease, 336 idler pulleys, 338 light oil, 337 worn parts replacement, 340 Printer calibration axes, 185 accurate X-axis movement, 188 multiple tests X-axis movement, 189 tools, 186 X-axis movement, 187 Y axis measurement, 190 Z axis 50mm measurement, 193 Z axis measurement, 192 endstop setting (see Endstop setting) extruder, 193 filament 0mm, 195 filament 100mm and 120mm, 195 filament loaded, 194 overrun, 198 process, 194 Repetier-Host filament extrusion, 196 underrun, 197, 199 frame and chassis, 203 print bed level point four measurement, 202 point one measurement, 201 point three measurement, 202 point two measurement, 201 process, 200 stepper drivers module, 184–185 Printer control, 292 Printer-specific upgrades MakerBot Replicator 1 Dual ABS, 411 advantages, 411 AluCarriage, 415 Aluminum Arm, 417 disadvantages, 411 enclosure, 418 extruder upgrade/filament drive, 413 heated print bed, 415 modification, 412 upgraded Replicator 2, 413

MakerBot Replicator 2 acrylic build plate, 421 AluCarriage single, 425 aluminum arm, 425 Alu-X-ends, 421 enclosure, 423 extruder upgrade, 425 features, 420 modification, 419 Printrbot Simple, 386 advantages, 385 auto bed leveling, 388 belt drive upgrades, 386 heated print bed, 391 LCD panel, 388 limitation, 385 onboard mount, 388 power supply, 390 spool holder, 391 Prusa i3 (see Prusa i3) Prusa Mendel i2 cooling fan, 395 LCD panel, 393 modification, 393 platform, 392 print bed adjusters, 396 RepRap variant, 391 spool holder and filament guide, 394 Y-axis belt tensioner, 395 Z-Axis Fix, 397 Z-height adjuster, 395 Print quality problems, 485 sagging ABS, 279 designing support, 280 large gap (bridge), 279 PLA, 279, 281 repair filaments, 279–280 small gap, 279 splitting, 278 temperature, 276 warping, 277 Printrbot, 59–60 Print surface calibration print axis measurement, 237 compilation, 235 filament issues, 238 MakerBot Replicator, 236 measurements, 235 OpenSCAD, 235 Printrbot, 236 RepRap test cube, 237–238

493

■ index

Print surface (cont.) preparation ABS juice (see Acrylonitrile butadiene styrene (ABS) juice) blue painter’s tape (see Blue painter’s tape) cleanup, 208 filament type, 207 Kapton tape (see Kapton tape) surface treatments, 223 printing process, 233 slicer calibration, 224 bed size, 226 bed temperature, 229 extrusion temperature, 229 filament diameter, 227 filament settings, 231 final dilog, 230 firmware type, 225 nozzle diameter, 227 printer settings, 232 print settings, 231 Repetier-Host, 232–233 welcome wizard, 225 Thingiverse (see Thingiverse) Z-height, 223 adjustable bed, 224 four point mounted bed, 224 procedures, 223 RepRap printers, 224 Professional grade Delta Micro Factory Corporation, 56 higher quality, 55 Lulzbot, 56 MakerBot Industries, 55 MakerBot Replicator 2, 57 MakerBot Replicator Desktop, 56 Pronterface, 31 Prusa i3 auto Z-probing electromagnet, 408 Marlin firmware, 411 own copy modification, 411 servo connectors (RAMPS), 410 sled mounted, 407 12-volt relay, 408 wiring, 409 external power supply, 402 features, 400 flex coupler, 404 graphic LCD panel, 377, 400 plastic parts, 400 RAMPS fan, 403 RepRap variant, 400 spool holder and filament guide, 406 USB cable relocate, 405 Y-axis cable strain relief, 403

494

Prusa iteration 3, 66 Prusa Mendel i2 cooling fan, 395 filament management, 372 heated print bed, 375 LCD panel, 376, 393 LED light, farkles, 371 modification, 393 platform, 392 print bed adjusters, 396 RepRap variant, 391 spool holder and filament guide, 394 Y-axis belt tensioner, 395 Z-axis fix installation, 399 lower mounts, 399 two cylinders, 398 Z-height adjuster, 379, 395 Prusa Mendel iteration 2, 64

„„         R RedPah web site, 456 Repairs. See Corrective maintenance Repetier-Host G-code pane, 35 installation Advanced page, 161–162 Behavior page, 159–160 communication tab, 158 Dimension tab, 160–161 preflight tests, 163 printer controller, 156 process, 158 object pane, 33 print control pane, 36 slicer pane, 34 RepRap design definition, 63 DIY Tech Shop, 68 MakerFarm, 68–69 NextDayRepRap, 68 NorCal-RepRap, 68 Prusa iteration 3, 66 Prusa Mendel iteration 2, 64 Prusa/Prusa Mendel, 64 Ultibots, 68 Retraction setting, 255

„„         S SeeMeCNC, 59 SeeMeCNC’s Orion Delta printer, 61 Shapeways, 456

■ Index

Sharing 3D models Bld3r, 457 Cuboyo, 457 etiquette checking license, 458 comments, 460 design annotation, 459 licensing designs original, 457 uploading appropriate things, 459 limitation, 455 Repables, 457 selling, 456 Thingiverse, 456–457 account creation, 464 description and instruction, 465 license options, 463 monitoring feedback, 466 name selection, 465 OpenSCAD file, 465 Prusa i3 dial gauge creation, 460 publishing, 465–466 rendered object, 462–463 uploading photo, 465 uploading source files, 464 YouMagine, 457 Yeggi, 457 S-hook, 472 Slic3r, 22 Slicer, 289 adhesion problem ABS and PLA, 272 anchors, 275 brim setting, 274 combat lifting, 276 cracking/warping, 272 first-layer speed, 275 .gcode file, 271 lifting, 272 print bed, 272 raft printed object, 274 temperature settings, 273–274 filament temperature limitation, 277 layer inconsistency, 290 oozing, 289 orientation dollhouse table, 282–283 object overhang, 285 object print preview, 287 reducing overhang, 286 reoriented object, 286 Repetier-Host, 284 rotating and translating objects, 284–285 poor extrusion, 287

print quality (see Print quality) scaling, 281–282 Smartfriendz, 468 Smartrap printer, 467 build guide, 469 components, 468 hardware and electronics, 469 printing plastic parts, 468 Smoke test, 123 Software problems firmware, 293 printer controller, 291–292 slicer (see Slicer) Soldering iron, 90 Spares cost, 343 printed parts, 342 printing spares, 341 replacement parts, 343 Ultimaker, 340 Wanhao, 341 Stepper driver, 343 Stepper motor, 343

„„         T Thingiverse, 13, 239, 456–457 account creation, 464 description and instruction, 465 download curtain rings, 241 instructions tab, 242 Repetier-Host, 242 license options, 463 monitoring feedback, 466 name selection, 465 OpenSCAD file, 465 Prusa i3 dial gauge creation, 460 publishing, 465–466 rendered object, 462–463 SD card holder, 239 search page, 240 Stretch bracelet, 239 uploading photo, 465 uploading source files, 464 Whistle, 239 3D printer acquisition rule, 72 build volume, 74, 81 buying, 81–82 characteristics, 82 consumer grade (see Consumer grade) filament, 75 Hobbyist grade (see RepRap design)

495

■ index

3D printer (cont.) hot end design adjustable print bed, 79 all-metal hot ends, 75 auto bed leveling, 80 electronics cooling fan, 80 filament cartridge system, 79 filament cleaner, 79 filament spool holder, 79 heated print bed, 79 LCD panel, 78 mounting orientation, 77 network connection, 79 PEEK body with PTFE liner, 77 print bed fan, 79 SD card reader, 78 wireless support, 79 object designs and modifications, 455 professional grade (see Professional grade) Prusa i3 material, 70 rewarding and educational, 73 sharing (see Sharing 3D models) 3D printer building acetone, 101 break recommend, 112 clean and clear workspace, 110 complete kits, 104 component kit hot end kit, 106 RAMPS kit, 107 dial gauge, 99 electrical skills, 103 electronics component testing, 118 cut wires, length, 119 high-temp wire, 119 insulation plug, 121 LCD cables, 119–120 load spread, 123 rushing, 118 stress relief plastic wire wrap, 122 zip ties, 119 engineering logbook, 112 farkle function, 112 frame components bolt/rod hole, 113 lost nuts and small bits, 116 nut traps, 115 RepRap Prusa i2 measurement, 114 staining/painting, 116 stripped bolts, 115 test-fit, 114

496

threaded rod clean, 114 torque, 115 hammer, 100 hands clean, 111 hardware materials, 109 material bill checking, 111 moving parts align pulleys, 117 backward, 117 belt tensioners, 117 flex axis, 117 oiled parts working, 116 repository, 117 smooth/threaded rods, 116 no duct tape, 111 optional tool smooth/threaded rods, 116 butane torch, 100 canned/compressed air, 98 dial gauge, 99–100 file set and sandpaper, 99 hammer, 100 hobby knife set, 98 MakerBot Replicator 2, 99 scissors, 100 small brush, 98 small vacuum, 98 small wrenches, 100 parts-only kits, 105 preflight checks axes move checking, 125–126 controller software connect, 123 endstops checking, 124 extrusion test, 127 heaters test, 126 set endstops, 123 smoke test, 123 reading instructions, 110 recommended tool ABS and PLA, 101 advantage, 94 brass brush, 102 drill bits, 96 electric screwdriver, 97 fire extinguisher, 94 fume extractor, 95 heat gun/hot air gun, 97 Kapton tape, 102 required tool, 87 carpenter’s square, 89 ceramic screwdriver, 93 digital caliper, 88 ESD, 88

■ Index

hobby knife set, 88–89 multimeter, 92–93 soldering iron, 90–91 wire strippers, 90 SAE and metric, 111 skills definition, 101 electrical skill, 102 mechanical skill, 101–102 tool quality, 86 upgrades and convenience accessories, 112 3D printer hardware ABS vs. PLA, 49 axes movement, 37 build platform, 43–44 electronics, 44 extrusion mechanism, 41 filament types, 47 frame material, 45 linear bearings, 38 MakerBot Replicator 2, 38 Prusa Iteration 3 printer, 39 RepRap iteration 3, 38 robot, 37 stepper motor, 40 switching filament, 49 3D printer maintenance, 297 adjustment tasks (see Adjustment tasks, 3D printer) clean and clutter, 298 inspection tasks (see Inspection tasks, 3D printer) observations, 300 timing, 299 tool organizational styles, 299 unplugging, 299 3D printer network print server OctoPi Control tab, 169–170 GCode Viewer tab, 170–171 OctoPi connection area, 168–169 OctoPi main window, 168–169 Terminal tab, 171–172 Terminal tab, 171–172 time-lapse movie, 173 Timelapse tab, 172 Raspberry Pi definition, 164 hardware, 166 Linux, 166 Mac OS X, 165 software, 168 Windows, 165

3D printer usage ideas household solutions closet accessories, 472 furniture, 475 mechanical hardware, 473 prototyping, 470 printing costs, 470 spawning (see Smartrap printer) 3D printing additive manufacturing, 4–5 additive manufacturing, 4–5 easy to use, 50 FFF work, 5 hardware (see 3D printer hardware) maintainability, 52 print quality, 51 reliability, 51 software (see 3D printing software) subtractive manufacturing, 4 3D printing software CAD software Blender, 10 manifold, 9 OpenSCAD, 12 Thingiverse, 13 CAM software G-code, 15 MakerWare, 18 Slic3r, 22 filament properties, 23 firmware, 26 printer control applications, 30 printer server pronterface, 31 Repetier-Host (see Repetier-Host) Threaded rod–driven mechanism, 138 Thread spool creation characteristics, 436 defining code, 436 documentation, 438 modules, 438 parametric code, 437 Thrust bearing, 337 Trimming, 443 Troubleshooting baseline definition, 247 causes, 249 observations and recording, 248–249 strategy implementations, 250 Typewriter stand, 345

497

■ index

„„         U, V

„„         Y, Z

Ultibots, 68 Ultimaker, 340

Y-axis belt MakerBot Replicator 2/2X drive belt adjustment, 361 idler pulley, 362 intermediate shaft, 363 MakerBot Replicator Dual drive belt, 360 intermediate shaft, 362 left and right side belts, 359

„„         W Wanhao, 341 Weld-On #4, 351 Wire strippers, 90

„„         X X-ends, 342

498