Murphy's law, road to the platypus

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matteej
Posts: 23
Joined: Wed Oct 17, 2012 8:09 pm
Location: Netherlands
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Murphy's law, road to the platypus

Post by matteej »

Hello Printer people!

First of all, let me introduce myself:
I'm a dutch selectively lazy mechanical engineering student with a dream: To print my very own Perry the Platypus.
I had been contemplating to buy a 3D printer for this sole purpose for a while when I met someone named Guillaume Feliksdal on my campus demonstrating his printer design.
After a short introduction and some Q&A I went home and immediately ordered a printer kit (With a little financial aid from my gadget-loving dad).
3 weeks of impatiently keeping track of the mailman's whereabouts had gone by when it finally arrived!
After ripping open the box without regards for personal safety, a pile of parts which when properly composed had the potential to become a 3d-printer quickly found its way to my workbench.
After some hours of building (using a 1.0E manual for a 1.5 printer), an amount of caffeine enough to kill a small elephant, and many many cable ties later the printer was finally ready.
Unfortunately that was the moment when I realized that someone named "Edward Aloysius Murphy, Jr" had spoken wise words. I will elaborate this using some problem-solution combinations. These are all based on true stories.

Problem:
The printer bed can't reach the extruder, because the Y-motor touches the X-motor.
http://satoer.com/onlineimages/felixpri ... age025.jpg
(http://www.felixprinters.com/forum/view ... p?f=7&t=90)
My solution:
I placed about 6 washers on the table-holding-screws to increase the height.
washers
washers
Someone elses elegant solution:
Use a new X-motor holder or file a piece off of it.

Problem:
Some stuff in Repetier Host doesn't work
Solution: try running it as admin.

Problem:
The first test prints were not round as they should be
Solution:
Adjust the extruder height (first layer has to be squished), and make sure the bed is warm enough

Problem:
The reset button kept being pushed in by the box
Solution:
Drill out the hole some more.

Problem:
The hot end kept plugging up and wasn't really consistent in extruding fillament. Some times nothing came out, other times the fillament was way too thin.
Thin fillament
Thin fillament
Solution:
I ordered a new hot end.
A better solution:
Drill out the Hot-end with a 0.3 mm drill
I accidentally deformed the hot end while calibrating by dragging it over the table. That little hole is delicate!

Problem:
The extruder stopped extruding halfway through an 8-hour print.
Solution:
Don't place the printer in a non-isolated closed area during long prints
The temperature in the box became too hot.

Problem:
The wires don't fit in the box
Solution:
Leave the top off :)

Problem:
The extruded fillament kept shifting to the right while printing
Shift
Shift
Solution:
The set-screw somehow managed to shake loose together with the extruder (don't ask me how, I really don't know).
After checking the opto-sensors, the potentiometers, the bearings, the fillament roll, and the other people in the area, I finally found the loose screw.

problem:
STL files don't load correctly into Repetier Host.
Solution:
The stl file is faulty, fix it using tools like these: http://cloud.netfabb.com/

Problem:
The hot end didn't fit behind its 'door'
Solution:
I cut off a piece of the door
Better solution:
Guillaume gave me a new door which fit perfectly

Problem:
The prints still stopped half way or were really messy
Solution:
I wisened up, and physically brought the printer to its God.
Guillaume performed some miracles on it, and after a lot of tinkering (and replacing parts) there it was... a functional printer!

At this point I presumed that this was the end of a long road full of troubleshooting. But my dear friend Murphy had some more tricks up his sleeve!

Problem:
Waking up and finding this attached to your hot end.
Fan duct trolling
Fan duct trolling
Fan duct trolling 2
Fan duct trolling 2
Solution:
Guillaume sent me some g-code to print a new air duct with
new duct
new duct
Problem:
the support material won't stick to the bed well enough
"support" material
"support" material
Solution:
Add a base layer to the support, or rotate the STL so that the support material is orientated differently

Most of these problems were fixed using a combination of feedback from Felix, reading existing posts on the forums, and a little bit of "common sense". Credits go out to this community, and Guillaume the printer-god.
Thanks to you all, I finally got around to printing my very own Perry the Platypusses!
perry 1
perry 1
perry 2
perry 2

Kjetilei
Posts: 334
Joined: Fri Mar 16, 2012 8:26 pm
Location: Stavanger, Norway

Post by Kjetilei »

Welcome matteej :)
Ouch! It's been a long and troublesome trip for you to get your Felix going!

The good part is that you have experienced most of the problems that can happen and have learnt the hard way through practical thinking how to fix it ;)

Your experience moving forward should definitely be more pleasant!

Good luck with your Felix :) Hope to hear more of your experiences/input to the forums.

satoer
Posts: 436
Joined: Mon Oct 01, 2012 8:00 pm
Location: Netherlands

Post by satoer »

Welcome to the club!
I’ve seen you read my topic also, so you have seen I also had a troublesome startup. But I’m happy to say that once you get to know your printer and software it’s quite a trouble-less machine. I’ve printed for a while now with zero troubles.
Today I printed my most complex and detailed thing till now: A double stage planetary gear set.
Image
I’m totally impressed with the quality of the printed parts. Even a machine drill for 2 minutes nonstop didn’t worn out the gears.
( http://www.thingiverse.com/thing:23030 )

So, don’t give up, after all the starter diseases you’ve got a nice machine!
My Felix 1.5 printed designs on Thingiverse
E3D V6 Hot end upgrade for your Felix
Tweezer bracket for your Felix
Led bar upgrade for your Felix

Kjetilei
Posts: 334
Joined: Fri Mar 16, 2012 8:26 pm
Location: Stavanger, Norway

Post by Kjetilei »

Satoer: did you print it out in high quality profile or regular production profile?

I have printed two copies of the single stage version with regular production profile. Works like a charm. I was never able to get it working with the old Igus bearings due to the backlash.

satoer
Posts: 436
Joined: Mon Oct 01, 2012 8:00 pm
Location: Netherlands

Post by satoer »

0,25 mm layerheight with infill of 100%
My Felix 1.5 printed designs on Thingiverse
E3D V6 Hot end upgrade for your Felix
Tweezer bracket for your Felix
Led bar upgrade for your Felix

matteej
Posts: 23
Joined: Wed Oct 17, 2012 8:09 pm
Location: Netherlands
Contact:

Post by matteej »

some of the stuff I've printed so far: http://www.thingiverse.com/matteej
Image
"minimum layerheight" profile (with added support)
Printed for someone I know who apparently is a huge fan.
Too bad the models are quite hard to find


Image
http://www.thingiverse.com/thing:34778
http://dl.dropbox.com/u/109755417/transmission.rar
Most of it is printed using "normal quality". unfortunately I didn't tension the fillament enough, so some of the top layers are a bit ugly.
The model is quite well designed.
not tensioning the fillament enough can lead to this
not tensioning the fillament enough can lead to this
Image
http://www.thingiverse.com/thing:12173
http://dl.dropbox.com/u/109755417/Gear_ ... _files.zip
An odd clock
Looks nice when attached to things like walls

Need some suggestions about what to print next.
The more useless it is, the more I like it.

http://www.thingiverse.com/thing:23030 is on the top of my list ;)

satoer
Posts: 436
Joined: Mon Oct 01, 2012 8:00 pm
Location: Netherlands

Post by satoer »

What do you mean with: "unfortunately I didn't tension the fillament enough"? The tension bearing on the fillament?
My Felix 1.5 printed designs on Thingiverse
E3D V6 Hot end upgrade for your Felix
Tweezer bracket for your Felix
Led bar upgrade for your Felix

matteej
Posts: 23
Joined: Wed Oct 17, 2012 8:09 pm
Location: Netherlands
Contact:

Post by matteej »

2012-12-02 14.29.27.jpg
does anyone have an idea about how I can prevent these small lines on the side where the machine went on to print the next layer?

It's printed with "minimal layerheight", 200 degrees Celcius extruder, 60 degrees bed, 2 base layers with 100 % filling, and support set on "exterior only"
satoer wrote:What do you mean with: "unfortunately I didn't tension the fillament enough"? The tension bearing on the fillament?
yes

After i turned the screw one time, the problem was resolved
Last edited by matteej on Sun Dec 02, 2012 2:55 pm, edited 1 time in total.

matteej
Posts: 23
Joined: Wed Oct 17, 2012 8:09 pm
Location: Netherlands
Contact:

Post by matteej »

and then there was the sudden onset of prints with only 1 cm height extruded, and a nice X+Y shift.
http://pastebin.com/bCa63kJT
and just when I was about to finish my first roll :(

I just fiddled the cables a little bit (and switched to another usb and power cable) and now I'm having no more shift, even after 2 more hours of printing :

has anyone experienced something similar?
I've been running the thing semi-nonstop for a week.

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gfeliksdal
Site Admin
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Joined: Sat Feb 25, 2012 10:40 pm
Location: Netherlands
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Post by gfeliksdal »

Hi Matteej, Very nice write-up on your experience :), too bad you had to experience almost all possible issues with the printer.

The issue you are encountering now, seems like a loose x-sensor connector. Either at the opto-sensor side or the electronics board. Tightening the screwterminals and checking the connector on the RAMPS electroncis should normally solve the problem. If that doesn't help maybe the cable or opto-sensor are broken.

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