® USER MANUAL
TABLE OF CONTENTS 1 WELCOME Safety and Compliance Specifications How it Works 2 SETUP Unpacking Your MakerBot Replicator 2X MakerBot Replicator 2X Diagrams Accessory Box Setting Up Your MakerBot Replicator 2X 10 11 12 14 16 3 STARTUP LCD Keypad Leveling the Build Plate Loading MakerBot Filament Unloading MakerBot Filament Troubleshooting 20 21 22 24 27 28 4 LCD MENUS Top Level Entries Utilities Menu Info and Settings Menu Active Build Menu 30 31 32 33 36 5 PRINTING FROM SD Making a Test Object T
TABLE OF CONTENTS 9 BASIC PRINTING Printing Examples Printing with Both Extruders 62 63 64 10 INTERMEDIATE PRINTING Print Quality Rafts Supports Troubleshooting Printing an Example 68 69 70 71 72 73 11 ADVANCED PRINTING Print Quality Temperature Speed 76 77 80 81 12 INTRODUCTION TO THINGIVERSE Creating an Account Navigating Thingiverse 84 85 85 13 USING THE CUSTOMIZER IN THINGIVERSE Customizing a Thing 88 89 14 FILAMENT Filament Basics ABS Filament ABS Filament Troubleshooting PLA Filament P
NOTES 5
1 Welcome This User Manual is designed to start your journey with the MakerBot® Replicator® 2X Experimental 3D Printer in the right direction. Your MakerBot Replicator 2X is optimized for ABS, a traditional thermoplastic that can be tricky and unpredictable. In order to achieve great results, you will need to experiment and tinker. That’s why it’s so crucial to take the time to learn about your new machine. In this manual, you will learn how to set up and start using your Replicator 2X.
SAFETY AND COMPLIANCE RADIO AND TELEVISION INTERFERENCE This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications.
SAFETY AND COMPLIANCE CONTINUED This safety alert symbol precedes each safety message in this manual. This symbol indicates a potential safety hazard that could harm you or others or cause product or property damage. CAUTION: In case of emergency disconnect power supply from wall socket. CAUTION: The socket outlet must be located near the equipment and must be easily accessible CAUTION: The Replicator 2X melts plastic during printing. Plastic odors are emitted during this operation.
HOW IT WORKS The MakerBot Replicator 2X Experimental 3D Printer makes solid, threedimensional objects out of melted MakerBot Filament. Your 3D design files are translated into instructions for the MakerBot Replicator 2X and read by the machine via SD card. The MakerBot Replicator 2X then heats the MakerBot Filament and squeezes it out through a nozzle onto a heated surface to build a solid object, layer by layer. This method is called Fused Filament Fabrication [FFF].
2 Setup When you set up your MakerBot® Replicator®2X Experimental 3D Printer, remember that it was built and packaged very carefully at the MakerBot Factory. We hope you’ll take your time and be just as careful unpacking it and getting set up.
UNPACKING YOUR MAKERBOT REPLICATOR 2X 1 Opening the Box 1a. Place the MakerBot Replicator 2X box on the ground. Open the box and remove the top cardboard sheet. 1b. Remove the MakerBot Replicator 2X User Manual. We recommend that you review the manual to guide you through the setup process and keep it handy as you unpack the contents of the box. If you find that anything described in the manual is missing, email us at support@makerbot.com. 1c.
MAKERBOT REPLICATOR 2X DIAGRAMS [1] GANTRY SYSTEM [2] LCD PANEL [3] HEATED BUILD PLATE 1 [4] BUILD PLATFORM [5] THREADED Z-AXIS ROD [6] ENCLOSURE DOOR HANDLE [7] FILAMENT GUIDE TUBES [8] EXTRUDER CABLE 3 [9] EXTRUDERS 5 [10] FILAMENT SPOOL 6 2 [11] SPOOL HOLDERS 4 8 7 10 9 11 12
MAKERBOT REPLICATOR 2X DIAGRAMS CONTINUED [1] FAN GUARDS 4 [2] EXTRUDER FANS [3] EXTRUDER NOZZLES [4] EXTRUDER LEVER ARMS [5] FAN BOLTS 1 2 5 [6] CARTRIDGE HEATERS [7] THERMAL CORES 6 [8] DRIVE BLOCKS 7 3 [9] EXTRUDER CABLE MOUNT Front view of extruders [10] MOTOR CABLE CONNECTORS [11] EXTRUDER MOTORS 8 [12] HEAT SINKS 9 10 [13] BAR MOUNT [14] SPACERS 11 [15] EXTRUDER CARRIAGE 12 13 15 14 Angled view of extruders 13
ACCESSORY BOX * 1 2 MakerBot ABS Filament [1 lb Spool] 1 1 Power supply and cable SD card 14 USB-A to USB-B cable 4 1 * Filament guide tubes Hex wrenches 2 Spool holders 1 MakerBot tape applicator 1 PTFE-based grease More options available at makerbot.
ACCESSORY BOX CONTINUED 3 Removing the Accessory Box 3a. Remove the two remaining protective foam pieces from the bottom of the MakerBot Replicator 2X’s box. 3b. Lift out the accessory box. This box contains the remaining items from the Accessory Box section. 4 Freeing the Extruders 4a. Use strong scissors or a wire cutter to cut the zip ties holding the gantry system in place. Discard the zip ties and the plastic pieces holding them in place. 4b.
SETTING UP YOUR MAKERBOT REPLICATOR 2X 5 Installing the Enclosure Door Handle 5a. Locate the handle kit in the accessory box. The kit includes your enclosure door handle and two buttonhead bolts. 5b. Open the enclosure door. To do this, reach through the top of the MakerBot Replicator 2X, push the door outward, and raise it to a 90° angle. 5c. Place the handle on top of the enclosure door. Align the holes in the ends of the handle with the pre-drilled holes in the enclosure door. 5d.
SETTING UP YOUR MAKERBOT REPLICATOR 2X CONTINUED 6 Installing the Filament Guide Tubes and Spool Holders 6a. Locate the two filament guide tubes. Insert one end of a filament guide tube into the hole in the top of one of the extruders. Push the filament guide tube in as far as it will go. Insert the end of the other filament guide tube into the hole on the top of the second extruder. Push the filament guide tube in as far as it will go. 6b.
SETTING UP YOUR MAKERBOT REPLICATOR 2X CONTINUED 7 Mounting the Filament Spool 7a. Open the box containing your starter spool of MakerBot ABS Filament. Remove the spool from its plastic bag. 7b. Mount the spool on the left spool holder [when viewed from the back of the Replicator 2X]. Orient the spool so that it will unwind counterclockwise. Push the spool onto the spool holder until it locks. Do not let the filament uncoil or tangle as you load the spool onto the back of the MakerBot Replicator 2X.
SETTING UP YOUR MAKERBOT REPLICATOR 2X CONTINUED 9 Attaching the Power Supply 10a. Locate the power supply and cable. Attach the cable to the power supply. 10b. Ensure that the power switch on the MakerBot Replicator 2X is set to the OFF position. 10c. Insert the power supply connector into the power input port on the back of the MakerBot Replicator 2X. Ensure that the flat side of the connector faces down.
3 3 CHAPTER Startup After you switch on the MakerBot® Replicator® 2X Experimental 3D Printer, the LCD panel will light up and display text. This text is the beginning of the Startup Script. The Startup Script will guide you through leveling the build plate, loading MakerBot ABS Filament, and creating your first 3D print.
START UP THE LCD KEYPAD • A solid red M means the MakerBot Replicator 2X is working. • A blinking red M means the MakerBot Replicator 2X is waiting for user input. The left arrow often allows you to go back or cancel an action. Four arrow buttons surround a central M button. Use the arrows to navigate through the LCD menus and the M button to make selections.
LEVELING THE BUILD PLATE ! Why Leveling Is Important • If the build plate is too far from the extruder nozzles, or if one part of the plate is farther away from the nozzles than another part, your 3D prints might not stick to the build plate. • If the build plate is too close to the extruder nozzles, the build plate can block the MakerBot Filament from extruding from the nozzles. This can also tear the Kapton tape applied to the build plate and scratch the aluminum surface underneath.
LEVELING THE BUILD PLATE CONTINUED 2 Adjust Each Knob Again The script will prompt you to adjust each knob again. This allows for fine tuning. This time, the Support card should slide between the build plate and nozzles with more friction. 3 Confirm your Adjustment After the second set of adjustments, the nozzles will move to the center of the build plate. Confirm that the MakerBot Support card slides between the nozzles and plate with a moderate amount of friction.
LOADING MAKERBOT FILAMENT 1 Remove the Enclosure Lid Lift the enclosure lid from the top of the MakerBot Replicator 2X and set it aside. 2 Detach the Filament Guide Tube on the Right Filament Guide Tubes Extruders Locate where the right-side filament guide tube enters the right extruder. Detach the guide tube by gently pulling it out of the extruder. 3 Feed the Filament through the Filament Guide Tube Free the end of the MakerBot ABS Filament from your starter spool.
LOADING MAKERBOT FILAMENT 4 CONTINUED Press the M to Begin Heating the Right Extruder After you feed the MakerBot ABS Filament all the way through the filament guide tube, press the M button on the LCD panel. The MakerBot Replicator 2X will start to heat the right extruder. CAUTION: Do not touch the extruders while they are heating — they heat to 230° C. 5 Press the M Press the M to continue After the extruder reaches 230° C, the LCD panel will prompt you to load filament into the right extruder.
LOADING MAKERBOT FILAMENT 7 CONTINUED Stop Extrusion After a few moments, you should see a thin string of the MakerBot ABS Filament come out of the right extruder nozzle. The filament might curl and then straighten; this is normal. Press the M button to stop extrusion. NOTE: Don’t be surprised if the plastic that initially comes out of the nozzle is not the color you expected. This is filament left over from testing.
LOADING MAKERBOT FILAMENT 9 CONTINUED Remove the Extruded Plastic Wait a few minutes for the extruded ABS plastic to cool, then pull it away from the right extruder nozzle. You can discard this extra plastic. CAUTION: Do not touch the nozzle; it may still be hot. Don’t leave plastic clinging to the extruder nozzles. This can cause newly extruded plastic to stick to the nozzles instead of the build plate.
TROUBLESHOOTING Can’t load filament? If you are having problems loading filament into one of the extruders, perform the following steps: 1. Go to the LCD panel and select Utilities > Filament Options > Unload. This option heats the extruders. 2. Set the extruder arm to the open position. 3. Make a fresh cut at the end of the filament. It is important that the filament have nobends in it. If it does, cut off the bentsection of filament. 4. Insert the filament into the hole at the top of the extruder.
TROUBLESHOOTING CONTINUED Can’t unload filament? If you cannot unload filament from one of the extruders, do the following: 1. Go to the LCD panel and select Utilities > Filament Options > Unload. This option heats the extruders. 2. Set the extruder lever arm to the open position. 4. Try pulling the filament out of the extruder again.
4 LCD Menus This chapter describes the menus and options available in the LCD panel on the MakerBot Replicator 2X.
LCD MENUS THE LCD KEYPAD The LCD Keypad includes four arrow buttons surrounding a central M button. • Use the arrows to navigate through the LCD menus and the M button to make selections. • The left arrow often allows you to go back or cancel an action. • A solid red M means the MakerBot Replicator 2X is working. A blinking red M means the MakerBot Replicator 2X is waiting for user input.
UTILITIES MENU THE UTILITIES MENU The Utilities menu contains controls for your MakerBot Replicator 2X and scripts for processes like loading filament and leveling the build plate. Fig. 4.1 Fig. 4.2 Monitor Mode. This entry displays the current temperature of your extruders and build plate. The display is updated as the temperatures change. Change Filament. This entry launches scripts that walk you through loading and unloading filament.
UTILITIES MENU CONTINUED Run Startup Script. This entry launches the startup script. The Startup Script runs automatically the first time you power on the MakerBot Replicator 2X. The Startup Script walks you through the steps for leveling your build plate, loading filament into the right extruder, and printing from the SD card. To exit the Startup Script, press the left arrow button. You will not be able to exit the Startup Script until the leveling portion of the script begins.
INFO AND SETTINGS MENU THE INFO AND SETTINGS MENU The Info and Settings menu displays information about your MakerBot Replicator 2X and allows you to change settings on your MakerBot Replicator 2X. [Fig. 4.3] Fig. 4. 3 Fig. 4. 4 Bot Statistics. This entry displays the total build time, in hours and minutes, during the lifetime of your MakerBot Replicator 2X. It also displays the duration of the last completed build. General Settings.
INFO AND SETTINGS MENU CONTINUED Accelerate. This entry toggles acceleration ON and OFF. Acceleration is set to ON by default. Acceleration allows your MakerBot Replicator 2X to operate more smoothly. If you set Acceleration to OFF, do not use printing speeds faster than 45mm/s. Heat Hold. This entry tells your MakerBot Replicator 2X to continue heating your extruders after a build is cancelled. You can set the hold time from one minute to thirty minutes. To turn this setting off, set it to zero minutes.
ACTIVE BUILD MENU THE ACTIVE BUILD MENU The LCD panel includes options and settings for use during printing. [Fig. 4.5] To access these settings during a print, select the left arrow. Fig. 4. 5 Pause. This entry allows you to stop a print briefly. During Pause, your extruders and build platform will not move from their current locations. Use Pause only to stop a print briefly. MakerBot does not recommend allowing a heated nozzle to remain stationary and in contact with your print for long period of time.
ACTIVE BUILD MENU CONTINUED Fig. 4. 6 Fig. 4. 7 Z Pause Height. This entry allows you to pause your print at a set height. When you select this option, you will see two additional settings: Z Position and Pause Active. [Fig. 4.6] To set the pause height, scroll to Z Position, press the M button, and use the arrows to increase the pause height in millimeters. Press the M again to confirm the height. Scroll to Pause Active and use the M button to toggle the setting ON and OFF.
5 Printing from SD Your MakerBot Replicator 2X includes an installed SD card. This card contains sample objects so you can start printing immediately. This chapter will walk you through the steps to print sample objects.
MAKING A TEST OBJECT FROM THE SD CARD LOCATE THE SD CARD The MakerBot Replicator 2X includes an SD card preloaded with files for making test objects. The SD card is located in the SD port, directly behind the LCD panel. Make sure the SD card is pushed firmly into the SD port. EXAMPLE: PRINTING THE CHAIN LINKS In this section, we will print the chain links object from the SD card. To do this: SELECT A PROJECT FROM THE SD CARD The final task in the Startup Script is to print an object from the SD card.
MAKING A TEST OBJECT FROM THE SD CARD CONTINUED CHAIN LINKS File Name: Chain Links Make Time: 12 Minutes COMB File Name: Comb Make Time: 14 Minutes MR JAWS File Name: Mr Jaws Make Time: 18 minutes Design By: Sal Thingiverse: 28405 Design By: repraprook Thingiverse: 1140 Design By: Mahoney Thingiverse: 14702 NUT AND BOLT SET File Name: Nut and Bolt Make Time: 27 minutes STRETCHY BRACELET File Name: Stretchlet Make Time: 16 minutes CUPCAKE File Name: Cupcake Make Time: 52 minutes Design By: aubenc
TROUBLESHOOTING The Replicator 2X doesn’t recognize the SD Card If your MakerBot Replicator 2X does not detect that there is a card in the SD slot, make sure the SD card is: • an SDSC card formatted for FAT16 • no larger than 2GB. Your MakerBot Replicator 2X can read only cards that meet these requirements. The default SD card that is shipped with your MakerBot Replicator 2X is formatted correctly and is of the correct size.
6 File Types This chapter describes the different types of files you will encounter while using your MakerBot Replicator 2X. STLs, OBJs and Things are ways to store 3D models. GCode and X3G are sets of instructions for your MakerBot.
FILE TYPES STL An STL is a widely used type of 3D model file. It consists of surfaces made up of triangles. Each triangle has an inner side and an outer side. The outer side is called the normal. In a well-formed STL, all the normals face outwards and the surface is continuous, with no holes. When a model meets these standards, it is referred to as manifold. STLs with normals that face inwards (inverted normals) may be printable, but a manifold model is considered a prerequisite for 3D printing.
FILE TYPES CONTINUED MakerWare automatically converts GCode to X3G when sending a file to your printer or saving to an SD card. To view the GCode, open the Make dialog and make sure it is set to Export to a FiIe. When the Export dialog appears, select GCode from the dropdown menu at the bottom of the window. You can open your GCode file in any text editor.
NOTES FILE TYPES 45
7 MakerWare MakerBot MakerWare is software that prepares 3D models for printing and turns them into instructions for your MakerBot Replicator 2X. Using MakerWare, you can prepare OBJ and STL files to be printed. You can also use MakerWare to customize print settings for the objects you make on your Replicator 2X.
DOWNLOADING AND INSTALLING MAKERWARE 1. Go to http://makerbot.com/makerware. 2. Choose your operating system from the platform drop-down menu. [Fig. 7.1] Fig. 7.1 3. Click the Download button and save the .exe or .dmg file to your local computer. 4. Open the saved file and follow the directions to install the MakerWare software. NOTE: During Windows installation, a separate installer window will open and prompt you to install device drivers.
EXPLORING MAKERWARE Open MakerWare and take a look around. The following buttons and menus appear: Fig. 7.2 HOME VIEW Click this button to reset MakerWare to the default view of the build area. 48 +/Click these buttons to zoom in and out. You can also use the scroll wheel on your mouse to zoom in and out.
EXPLORING MAKERWARE CONTINUED LOOK [Fig. 7.3] Click the Look button or press the L key to enter Look mode. In Look mode, you can: • Left-click and drag the mouse to rotate your view of the object. • Hold down shift, left-click, and drag the mouse to move your view of the object. • Click on the Look button again or press the L key to view the Change View submenu. Top: View the object from the top. Side: View the object from the side. Front: Default view. View the object from the front side. Fig. 7.
EXPLORING MAKERWARE CONTINUED TURN [Fig. 7.5] Click the Turn button or press the T key to enter Turn mode. In Turn mode, you can: • Left-click and drag the mouse to rotate the object around (0, 0, 0) the X,Y, and Z-axes. • Click the Turn button again or press the T key to view the Change Rotation submenu. X: Specifies rotation around the X-axis, in degrees. Y: Specifies rotation around the Y-axis, in degrees. Z: Specifies rotation around the Z-axis, in degrees. Reset Rotation.
EXPLORING MAKERWARE CONTINUED Maximum size. Changes the scale of the object to the maximum that can be printed by the MakerBot Replicator 2X. Reset Scale. Resets the object to the last saved scale. OBJECT [Fig. 7.7] Click twice to open the Object Information submenu. The Object Information submenu allows you to choose which extruder will print each object on your build plate. For details on printing objects with dual extrusion, see the chapter on Basic Printing. Fig. 7.
MAKERWARE MENUS FILE New: Opens a new MakerWare window. EDIT Undo: Undoes the last action. Open: Opens a new object file. If a file is currently open, you will be prompted to save it first. Redo: Redoes the last action. Add: Adds a new object to the current plate. Copy: Copies object. Recent: Displays a list of recently opened files. Paste: Pastes object. Examples: Provides a list of example files to print. Delete: Deletes selected object. Cut: Cuts object. Select All: Selects all objects.
MAKERWARE MENUS CONTINUED MAKERBOTS Upload Firmware: Checks for the latest version of the firmware. Prompts you to upload the latest if the firmware is out of date. Onboard Preferences: Allows you to change the default settings for the MakerBot Replicator 2X. For advanced users. Type of MakerBot: Allows you to specify the type of MakerBot Replicator you are using during the session.
SHORTCUT KEYS SELECTING AN OBJECT • To select a single object, left-click with the mouse. • To select two objects, select one object, hold down the Shift key and select the other object. Release the Shift key. • To select multiple objects, select one object by clicking with the left mouse button, hold down the Shift key, select additional objects, and release the Shift key.
TROUBLESHOOTING MakerWare cannot detect my MakerBot Replicator 2X When MakerWare cannot connect to the MakerBot Replicator 2X, that usually means you have to restart Conveyor. Conveyor is a background service that runs as part of MakerWare and manages the connection to your MakerBot Replicator 2X. To restart Conveyor: 1. Go the Services menu. 2. Choose Restart Background Service. 3.
8 Preparing to Print MakerWare allows you to open files, resize objects, create new object files, and save those files in multiple formats. This chapter will describe how to perform these tasks.
DOWNLOADING FILES FILE FORMATS FOR MAKERWARE MakerWare can open the following file types: MakerWare can export to the following file types: • GCode • X3G • S3G • OBJ • STL • THING For details on file types, see the chapter titled “File Types.” MakerWare can save the following file types: • STL • THING DOWNLOADING A FILE FROM THINGIVERSE To import a file from Thingiverse into MakerWare, you must first save the file to your local computer.
IMPORTING AND MOVING OBJECTS The files FlatIron.stl and Woolworth.stl are now ready to be opened in MakerWare. The following examples will make use of these two files. IMPORTING A FILE FROM A MODELING APPLICATION To import a file from a 3D modeling application into MakerWare: 1. In the 3D modeling application, save the file as either a binary STL file, an ASCII STL file, or an OBJ file. Fig. 8. 3 2. Start MakerWare. Choose the File menu. Choose Open.
COPYING OBJECTS 3. To prepare for the next section, move the Flatiron model to the left side of the build plate. DUPLICATING OBJECTS [Fig. 8.4] In this section, we will copy an object. Currently, you should have the Flatiron model at the left side of your build plate. We will make a copy of the Flatiron model. To do this: 1. Click on the Flatiron model. A yellow outline will surround the object. Fig. 8. 4 2. Press the keys Ctrl+C or Command+C to copy the file. 3.
ADDING AND SCALING OBJECTS ADDING AN OBJECT TO THE PLATE In this section, we will add a second object to the plate. Currently, you should have the Flatiron model at the left side of your build plate. SCALING AN OBJECT In this section, we will scale our two models. Currently, you should have the Flatiron and Woolworth models on your plate. 1. Select the Flatiron model. 1. Click the Add button. 2. To scale the Flatiron model: 2. Navigate to the location of the file Woolworth.stl and select that file.
SAVING AND PRINTING A FILE SAVING YOUR MODEL AND TOOLPATH FILES To save an object or a plate with multiple objects, click the Save button. PRINTING YOUR FILE 1. Insert your SD card into an SD card reader attached to your computer. 2 . Click the Make button. The Save dialog gives you the option to save the contents of the build plate as an STL or Thing file. • If you want to open the file in an application other than MakerWare, you should save the file as an STL file.
9 Basic Printing This chapter will walk you through printing two objects using the default settings in MakerWare. It will also walk you through the steps to print a dual extrusion object. This chapter assumes you have already downloaded and installed MakerBot MakerWare. If you have not installed MakerWare yet, see the chapter on Installing MakerWare.
PRINTING EXAMPLES PRINTING THE TREE FROG To print this tree frog model, we will download the STL file from Thingiverse and then open and print the file with MakerWare. It is a simple design and does not need any adjustments made to it in MakerWare. 6. Start MakerWare. Choose the File menu. Choose Open. Navigate to the directory where you stored the file treefrog_45_cut.stl. The tree frog should appear in MakerWare. 7. Click the Make button. 1. Open a browser session and go to http://www.thingiverse.com.
PRINTING EXAMPLES CONTINUED 4. On the Thing page for the Owl statue, you will see a button that says Download This Thing! Click this button. 5. In the Downloads window, select the button Download All Files. Thingiverse will download the file OwlReDo1_fixed_sc.stl to your local computer. 6. Start MakerWare. Choose the File menu. Choose Open. Navigate to the directory where you stored the file OwlReDo1_fixed_ sc.stl. The owl should appear in MakerWare. 7. Click the Scale button twice.
PRINTING WITH BOTH EXTRUDERS To better understand how dual extrusion works, we will download a dual extrusion object from thingiverse. 1. Open a browser session and go to http://www.thingiverse.com. Fig. 9.3 2. In the Search field in the upper right of the page, enter “Lotus Flower”. 3. In the Search Result page, find Lotus Flower by rweaving. Click on the title link. 4. In the Thing page for the Lotus flower, you will see a button that says Download This Thing! Click this button. 5.
PRINTING WITH BOTH EXTRUDERS CONTINUED 10. Click on the point of an outer petal from the first layer to highlight that object. 11. Click twice on the Object button. 12. In the Object Information submenu, in the Extruder field, select an extruder to print Lotus_color1.stl. [Fig. 9.4] 13. Click on the point of an outer petal from the second layer to highlight that object. 14. Click twice on the Object button. 15.
NOTES BASIC PRINTING 67
10 Intermediate Printing This chapter is for users who are ready to start editing print settings in MakerWare instead of accepting the default settings. It will explain when and how to use helper disks with a print, when and how to use rafts and support with a print, and how to use the print quality settings in the Make 68 dialog in MakerWare.
PRINT QUALITY PRINT QUALITY In MakerWare, when you select the Make command or Make button, you can specify one of three preset printing profiles. [Fig 10.1] Your choices are: • Low. Prints an object with lower resolution, but with a shorter print time. • Standard. Prints an object with standard resolution. • High. Prints an object with higher resolution, but with a longer print time. Fig. 10.1 Quality Infill Number of Shells Layer Height Low 10% 2 0.30 mm Standard 10% 2 0.20 mm High 15% 2 0.
RAFTS RAFTS A raft is a flat base that is printed before the object. A raft can help your object stick securely to the build plate. [Fig 10.3] In MakerWare, when you select the Make command or Make button, you can check a box in the Make dialog to include a raft with your print. File Name: 3D mouse Design by: DDStarkey Thingiverse: 61909 Fig. 10.3 A raft consists of several layers forming a flat surface for your object to rest on.
SUPPORTS The Raft Won’t Come Off My Object If you can’t easily remove the raft from your object, try these solutions: • Create or edit a custom profile using the MakerBot Slicer and increase the “raftModelSpacing” setting by .1 mm. This will increase the separation between the raft and the model. • Create or edit a custom profile using the MakerBot Slicer and increase the “feedstockMultiplier” by .05 mm. The raft might be difficult to remove because too much plastic is being extruded.
SUPPORTS CONTINUED To print an object with supports: 1. Open MakerWare. Open the model you want to print. 2. Click the Make button or open the File menu and choose Make It. Fig. 10.6 3. In the Make dialog, ensure that the following boxes are checked: Raft: Select this checkbox to print your object on top of a raft. Supports: Select this checkbox to print your object with supports. [Fig 10.6] 4. Print the object as usual.
PRINTING AN EXAMPLE In this example, we will print the bird model shown earlier. To do this: 1. Open a browser session and go to http://www.thingiverse.com. 2. In the Search field in the upper right of the page, enter “Bird (for putting on things)”. 3. In the Search Result page, find Bird (for putting on things). Click on the title link. 4. In the Thing page for the bird, you will see a button that says Download This Thing! Click this button. Fig. 10.7 5. In the Downloads window, click on the file bird.
PRINTING AN EXAMPLE CONTINUED 8. The default size of the bird is very small. We will resize the object to increase its size. [Fig 10.11] Fig. 10.11 9. Click the Scale button twice. In the Change Dimensions menu, edit the following settings [Fig 10.12]: Uniform scaling. Ensure that this box is checked. Scale To. Set this field to 200.00% 10. Click the Make button or choose the File menu and choose Make It. 11. In the Make dialog, ensure that the following boxes are checked [Fig 10.13]: Raft.
NOTES INTERMEDIATE PRINTING 75
11 Advanced Printing This chapter describes the advanced printing options in the 76 MakerWare software.
PRINT QUALITY ADVANCED OPTIONS To use the settings under Advanced Options, you must select one of MakerWare’s base profiles (Low, Standard, or High). When you change any of the settings in Advanced Options, an asterisk will appear next to the profile name everywhere it appears in the Make dialog. The asterisk indicates that the base profile is no longer in its default state. These options provide control over specific slicing options.
PRINT QUALITY CONTINUED File Name: 20mm calibration box Fig. 11. 2 Infill. Everything that is neither shells, nor floor, nor roof is filled with an internal lattice called infill. [Fig. 11.2] Infill provides your object with an internal support structure. The number that you enter in this field defines the solidity of the printed object’s infill. Higher infill percentages will result in more threads of infill extrusion that are closer together.
PRINT QUALITY CONTINUED Shells. Every object you print must have at least one shell. You can add as many shells as you want and they will print as concentric perimeters on each layer. [Fig. 11.3] If the layer cannot accommodate the specified number of shells, the slicer will just fit in as many as possible. File Name: Rock Wall hold 1.0 Fig. 11. 3 Additional shells, like larger amounts of infill, add to an object’s strength, weight, and print time. Two or three shells are sufficient for most objects.
TEMPERATURE TEMPERATURE [Fig. 11.4] Temperature settings for the extruders and the build plate are grouped together under the Temperature tab. Fig. 11. 4 Extruders. The extruders will need to be heated to approximately 230° C to melt and extrude the plastic filament at normal operating speeds. Extrusion temperature is tied very closely to both extrusion speed and the material being extruded. If you are experimenting with either of those, you might need to experiment with extrusion temperature, too. Speed.
TEMPERATURE CONTINUED If you are experimenting with different materials or extrusion rates, you need to consider the properties of the material you are using. Additives in plastic, including coloring agents, can also affect a particular filament’s properties, so if you are having trouble with a new roll of filament, temperature might be the culprit. Build Plate. A heated build plate helps printed plastic objects to stick to the printing surface without warping.
SPEED CONTINUED Because moving filament through the extruder at higher speeds pulls heat out of the extruder more quickly, substantial increases in speed require increases in extrusion temperatures. MakerBot does not recommend extruder speeds higher than 120 mm/s. Speed while Traveling. Traveling is when the extruder moves without extruding filament. Because travel moves are not limited by the temperature at which the plastic can be extruded, they can be faster than moves that do include extrusion.
NOTES ADVANCED PRINTING 83
12 Introduction to Thingiverse Thingiverse is a website created by MakerBot. You can access the website at http://www.thingiverse.com. Thingiverse allows MakerBot users and others to share design files for 3D objects. You can download files from Thingiverse and print them on your MakerBot Replicator 2X. You can also upload your own original designs to Thingiverse for others to print. Thingiverse is always changing, so visit thingiverse.com regularly to check out new features.
THINGIVERSE CREATING AN ACCOUNT [Fig. 12.1] To create a Thingiverse account, click the Join Thingiverse button at the top right of any Thingiverse page. With a Thingiverse account you can: • • • • • • Fig. 12. 1 Fig. 12. 2 Access the Dashboard Publish Things Customize Things Like and Collect Things Follow other Users Launch Apps NAVIGATING THINGIVERSE To view the Thingiverse website, go to http://www.thingiverse.
THINGIVERSE CONTINUED • Browse all Things by Categories like Tools, Household, and Art. • View Apps created using the Thingiverse API. Create. Allows you to publish your own Things, create objects using the Customizer, start a Collection of other users’ Things, or publish an App using the Thingiverse API. Fig. 12. 4 Fig. 12. 5 Fig. 12. 6 Search. Allows you to search Thingiverse using simple text matching.
THINGIVERSE CONTINUED To show that you Made a Thing: When you print something downloaded from Thingiverse, it’s good manners to show your work. Fig. 12. 7 Fig. 12. 8 • Click the “I made one!” button in the right sidebar. [Fig. 12.7] • This will take you to a new page where you can upload an image and add a description of the Thing you made. • Click Create at the lower right corner of the page to save the record of your Made thing.
13 Using the Customizer in Thingiverse Customizer is an application available on thingiverse.com. Customizer allows users to change the parameters of an object before downloading the STL file and printing it. Customizer allows users to make changes to an object directly from Thingiverse, using an intuitive user interface. When a user clicks the Create Thing button, Customizer saves the user’s changes and creates an STL file that the user can download and print.
CUSTOMIZING A THING Fig. 13. 1 VIEWING CUSTOMIZABLE THINGS To view a list of Things that you can customize with the Customizer application: 1. Go to http://www.thingiverse.com. 2. On the home page, click the Explore link at the top of the page and then click Customizable Things. 3. Thingiverse will display the Customizable page, with a list of Things that you can customize with the Customizer application. Each customizable Thing has a set of parameters you can edit in Thingiverse.
CUSTOMIZING A THING CONTINUED Fig. 13. 2 SAVING AND DOWNLOADING YOUR CUSTOMIZATIONS After you change one or more parameters for a customizable thing, you can save your customizations and download the file for printing. To do this: 1. In the Customizer page, click the Create Thing button. 2. The Creating Your Customized STL dialog box appears. You can enter values in the following fields: Name: Name of the file for the customized thing.
CUSTOMIZING A THING CONTINUED EXAMPLE OF CUSTOMIZING A THING This section will walk you through the steps to customize a thing with the Customizer application, create the STL file, and download the STL file. We will customize the thing called Customizable Round Trays. To customize this thing: 1. Go to go to http://www.thingiverse.com. 2. On the home page, use the Search field in the upper right. Search for “Round Trays”. 3. In the Search Results page, find “Customizable Round Trays by walter”.
CUSTOMIZING A THING CONTINUED Tray Bottom: Specifies the thickness of the bottom of the tray, in mm. In our example, set to 2.0. Resolution: Specifies STL resolution. In our example, select Medium. [Fig. 13.3] Fig. 13. 4 7. To save your changes and create an STL file you can download, click the Create Thing button. 8. In the Creating Your Customized STL dialog, enter the following: Name: Name of the new STL file. In our example, enter “Customized Round Tray”.
CUSTOMIZING A THING CONTINUED Create Thing: Click this button to begin generating the STL file. [Fig. 13.4] 11. In the Thing page for your new file, click the Download This Thing button. 9. The Creating your Customized STL dialog box will display a message telling you that it is generating your file. Click the link Go to my Queue to see the status of the new file. 12. In the Downloads dialog box, select the appropriate file to download. 10.
14 Filament 94
FILAMENT BASICS Your MakerBot Replicator 2X Experimental 3D Printer uses ABS plastic filament, 1.75 mm in diameter, to print objects. [Fig 14.1] The Replicator 2X can also use 1.75 mm filament made from other plastics with similar properties. The filament used in 3D printing is also known as plastic welding rod and is used in other applications, but filament made for 3D printing needs to be more consistent in diameter. Fig. 14.
ABS FILAMENT ABS is short for Acrylonitrile Butadiene Styrene. It is made of a combination of those three plastics. The three plastics can be mixed in different proportions to formulate ABS intended for different uses. ABS is tough and somewhat flexible. ABS becomes softer with increased temperatures, but at the extrusion temperatures used in a MakerBot it remains fairly viscous. That means that ABS melts quickly inside the extruder but doesn’t drip during travel moves.
PLA FILAMENT PLA, or Polylactic Acid, is a biodegradable plastic with features that make it great for 3D printing -- it doesn’t give off bad-smelling fumes and it has a low rate of thermal expansion, so it doesn’t warp very much. PLA is harder and slightly brittle. It is more likely to snap than bend, but that does not mean that PLA is easily breakable. PLA also stays flexible for a short while as it cools.
15 Updating Firmware To ensure that your MakerBot Replicator 2X provides optimum performance, you must keep the firmware up to date.
FIRMWARE Fig. 15.1 Keeping your firmware up to date will ensure that your MakerBot Replicator 2X always operates at its best. When a new version of your bot’s firmware is available, MakerWare will display a message letting you know that it’s time to update. [Fig 15.1] To update your firmware, follow these steps 1. Locate the USB-A to USB-B cable that came with your MakerBot Replicator 2X and use it to connect your Replicator 2X to your computer. Fig. 15.2 Fig. 15.3 2.
16 Finishing Things After you print an object, you can smooth it, retouch it, and paint it. This chapter will describe one method of finishing a printed object and then give a broad overview of other methods.
FINISHING THINGS FINISHING AN OBJECT WITH PRIMER AND SANDPAPER This method of finishing requires a matte gray spray primer, lightweight painters’ spackle, and fine grit sandpaper. 1. Prime the object. For a smooth, even coat of primer, keep your hand moving as you spray the object and spray only in short bursts. 2. Sand the object. Use a fine grit sandpaper on the entire surface of the print. The primer will come off in places, revealing the layer lines.
17 Designing for 3D Printing 3D printers can make objects that more traditional manufacturing processes, like milling and injection molding, cannot, but it also comes with its own set of strengths and weaknesses. Keep these guidelines in mind when designing models intended for 3D printing to produce successful printed objects.
DESIGN GUIDELINES File Name: Massive Overhang Test Fig. 17. 1 Design by: thingster Thingiverse: 40382 OVERHANGS [Fig. 17.1] As your MakerBot prints your object, each layer of plastic rests on the one below. When an object has straight sides, a new layer will be fully supported by the previous layer. But when an object has parts that angle outwards (overhangs) some part of the new layer is unsupported.
DESIGN GUIDELINES CONTINUED There are two components to figuring out what detail size you can achieve on the X- and Y axes. First is positioning accuracy. Positioning accuracy tells us how precisely the extruder can find the spot it is looking for on a plane. X and Y positioning accuracy on your Replicator 2X is about .01 mm. That’s a number you should consider when modeling shallow surface detail, but for small stand-alone or protruding features, you will have to go larger than that.
NOTES DESIGNING FOR 3D PRINTING 105
18 Reference
GLOSSARY OF TERMS ABS: Acrylonitrile butadiene styrene, a widely used thermoplastic, and the primary material used for making things on the MakerBot Replicator 2X. BUILD PLATFORM: The support for the heated build plate. The build platform includes knobs for manual leveling. DRIVE GEAR: The gear that pushes the MakerBot Filament into the heated part of the extruder. DUAL EXTRUSION: A process in which two extruders loaded with two different colors or kinds of plastic work together to 3D print an object.
GLOSSARY OF TERMS CONTINUED MAKERBOT FILAMENT: 1.75mm diameter plastic welding rod. This is the feedstock for your MakerBot Replicator 2X. MakerBot Filament comes in ABS, PLA, and PVA plastics. The MakerBot Replicator 2X is optimized for ABS. MAKERWARE: Free software created by MakerBot that allows you to load, rotate, scale, and move 3D models and create the toolpaths the MakerBot Replicator 2X uses to build objects.
GLOSSARY OF TERMS CONTINUED THREADED ROD: The long metal rod behind the build platform that is threaded along its entire length. This rod allows the build platform to move up and down along the Z-axis. TOOLPATH: The set of instructions your MakerBot will use to build an object. Toolpaths for the MakerBot Replicator 2X must be saved as an X3G file. USB CABLE: A cable that allows your computer to communicate with the MakerBot Replicator 2X in order to update firmware. .
CONTACT US SUPPORT makerbot.com/support Our website has extensive documentation and troubleshooting information about your MakerBot Replicator 2X Experimental 3D Printer. It’s a great resource when you want to try to solve issues quickly on your own. support@makerbot.com If you ever need help resolving an issue with your MakerBot Replicator 2X, send an email to the address above to open a ticket with the MakerBot Support Team.
WARRANTY, RETURNS, AND REPLACEMENT POLICY MakerBot products do not carry a long-term warranty. Returns are possible only on unaffected items, within 14 days of receipt. After such time, all sales are considered final. “Unaffected” means a device has never been assembled, powered up, programmed, or otherwise changed. MakerBot cannot accept returns on purchased items that have had electrical power applied to them, or been otherwise programmed, changed, or affected.
INDEX A ABS 95–96 See also loading filament diagram 14 troubleshooting 96 accessory box 14–15 adding an object in MakerWare 51 advanced printing options 77–80 B bar mount location 13 bridging 103 build plate leveling 22 location 12 temperature 81–82 build platform location 12 build volume 8 C cartridge heaters location 13 clogging 97 copying objects See duplicating objects in MakerWare cracking 96 creating an account in Thingiverse 85 custom profiles 82 Customizer 89–92 D designing for 3D prints 103–104 ob
INDEX CONTINUED F fan bolts location 13 fan guards location 13 filament 95–97 See also ABS; See also PLA diameter 8 loading 24–31 troubleshooting 28 unloading 27 filament guide tubes diagram 14 installation 17 location 12 filament spool location 12 mounting 18 file formats MakerWare 57 file types 8, 43 OBJ 43 STL 43 Thing 43 X3G 44 finishing prints 101 firmware 99 Fused Filament Fabrication (FFF) 9 G gantry system, location 12 GCode 43 General Settings 34 guide tubes See filament guide tubes H heated build
INDEX CONTINUED N nozzle diameter 8 O OBJ files 43 overhangs 103 P physical dimensions 8 PLA 97 troubleshooting 97 positioning precision 8 powering on 19 power supply attaching 19 diagram 14 printing advanced options 77–80 cancel 36 change filament 36 examples from Thingiverse 63–65 from the included SD card 39, 40 pause 36 with both extruders 64 print quality 69, 77–80 PTFE-based grease diagram 14 Q quality 77 infill 78 layer height 79 shells 79 R rafts example 73 troubleshooting 71 resolution See print qu
INDEX CONTINUED T tape applicator diagram 14 temperature 80 of build plate 81 of extruders 80 thermal cores location 13 Thing files 43 saving 61 Thingiverse creating an account 85 customization 89–93 dashboard 85 downloading files from 57, 86 example prints 63 exploring 85 liking a thing 86 navigation 85 threaded Z-axis rod location 12 troubleshooting MakerWare installation 47 printing 96 rafts 71 unloading filament 29–30 U unclogging 97 unloading filament 27 unpacking 15 USB cable diagram 14 V viewing an
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