crystalmarksop
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crystalmarksop [2023/07/19 17:11] – colin | crystalmarksop [2024/01/22 17:54] (current) – [Rates] bdincau | ||
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====== Crystalmark Training SOP====== | ====== Crystalmark Training SOP====== | ||
- | Last edited: | + | Last edited: |
- | Tool Lead: [PLACEHOLDER]\\ | + | Tool Lead: Yanis Yankauskas\\ |
- | Contact: | + | Contact: |
- | + | ||
- | ====== CrystalMark ====== | + | |
====Training Checklist: | ====Training Checklist: | ||
Line 11: | Line 9: | ||
*Job Setup | *Job Setup | ||
*At FlashCut CNC and CrystalMark: | *At FlashCut CNC and CrystalMark: | ||
- | *At the computer: export .dxf -> DXF to G-Code Converter (optimize paths) -> export .ngc -> open .ngc in FlashCut CNC 4 application -> open DinoCapture 2.0 -> jog etching nozzle in z until piece of paper has difficulty sliding -> zero Z in FlashCut CNC 4-> jog up 1.2mm in Z -> set CrystalMark switch to on until there is a through hole in piece -> center red markers on hole in DinoCapture 2.0 -> jog X and Y to desired location -> zero X and Y -> Press start | + | *At the computer: export .dxf -> Zeroing |
*After cut: inspect and remove piece -> vacuum area | *After cut: inspect and remove piece -> vacuum area | ||
*Part Removal Cleaning | *Part Removal Cleaning | ||
*Vacuum | *Vacuum | ||
+ | *Sharps | ||
*Rates | *Rates | ||
====Safety Concerns==== | ====Safety Concerns==== | ||
- | * Inhaling large aluminum oxide abrasive is hazardous. Wear a mask and safety glasses during use | + | * Inhaling large aluminum oxide abrasive is hazardous. Wear a mask and safety glasses during use. |
- | * Silicon and glass pieces may have sharp edges. Handle with caution | + | * Silicon and glass pieces may have sharp edges. Handle with caution. |
* Keep hands clear of etching during operation. Press any key on the keyboard in FlachCut CNC to stop operation. | * Keep hands clear of etching during operation. Press any key on the keyboard in FlachCut CNC to stop operation. | ||
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- Turn on CrystalMark DV-1 (under table) | - Turn on CrystalMark DV-1 (under table) | ||
- Plug in camera to computer (USB connection) | - Plug in camera to computer (USB connection) | ||
- | - fixture | + | - Fixture |
- | Computer | + | |
- | - If DXF: load .dxf into the "DXF to G-Code Converter" | + | There are two ways to use the CNC: Etching with a .dxf file or manually etching: using .dxf file or manually \\ |
+ | \\ | ||
+ | If .dxf: | ||
+ | - At computer: Load .dxf into the "DXF to G-Code Converter" | ||
- For each shape in the display window, right click and select " | - For each shape in the display window, right click and select " | ||
- Select " | - Select " | ||
- | - open .ngc in " | + | - open .ngc in " |
- | - Jog the CNC down to the surface of your piece, use a piece of paper to shim the etching nozzle and piece | + | - open " |
- | - " | + | - Place the acrylic plate on the crystalmark mount |
+ | - Jog the nozzle into the hole | ||
+ | - " | ||
+ | - Jog the CNC down to the surface of your piece | ||
+ | - " | ||
+ | - After zero-ing the Z axis, move up in Z until Z is at 1.1 mm. This will be your cutting height. | ||
- Select " | - Select " | ||
- " | - " | ||
- | - Note that origin is displayed in "DXF to G-Code Converter" | + | - Note that origin is displayed in "DXF to G-Code Converter" |
+ | - Use tape and/or turn on vaccum to fixture part (optional) | ||
- Begin etching : " | - Begin etching : " | ||
- Monitor operation | - Monitor operation | ||
- Select any key while in " | - Select any key while in " | ||
- | - menu -> select desired slice height -> open Profile drop down menu again -> select “Discard current changes” (if greyed out and not selectable | ||
- | - Switch back to “Recommended” print settings for ease of use | ||
- | - Adjust infill percentage and support | ||
- | - Support can be generated using ether nozzle, typically nozzle one holds build material with nozzle two printing with dissolvable support material | ||
- | * PVA support material needs to be dried in PrintDry container for at least 10 hrs prior to printing | ||
- | - Ensure “Adhesion” is selected | ||
- | - Save the .gcode (file type Ultimaker 3 uses) or .ufp (file type Ultimaker S5 uses) file from Cura to a USB drive | ||
- | - Select “PREVIEW” tab on top of screen to preview print | ||
- | * Specific layer cross sections can be viewed by adjusting slider to the right of screen | ||
- | - Remove glass build plate (pull open clips first), bring to fume hood #3 (spray booth) | ||
- | - Spray build plate with IPA and wipe off with paper towel | ||
- | - Spray thin layer of hairspray on build plate to ensure bed adhesion | ||
- | - Reinstall build plate into printer (secure using clips) | ||
- | - Connect thumb drive to printer -> select desired file -> select print\\ | ||
- | Note: If adjusting advanced print settings, please do so after creating a separate/ | ||
- | ====Post Processing==== | + | If manual: |
- | | + | |
- | | + | - open " |
- | | + | - Place the acrylic plate on the crystalmark mount |
+ | - Jog the nozzle into the hole | ||
+ | - " | ||
+ | - Jog the CNC down to the surface of your piece | ||
+ | - " | ||
+ | - After zero-ing the Z axis, move up in Z until Z is at 1.1 mm. This will be your cutting height. | ||
+ | - Use tape and/or turn on vaccum to fixture | ||
+ | | ||
+ | | ||
+ | - Select " | ||
+ | - In " | ||
+ | - Jog X and Y to desired location, A hole will be made where the red lines intersect | ||
+ | - Select " | ||
+ | - Monitor operation | ||
+ | - Select " | ||
====Part Removal and Cleaning==== | ====Part Removal and Cleaning==== | ||
- | * Remove | + | |
- | * If support was used, submerge print in warm water for several hours to dissolve PVA filament. (prints can warp if submerged | + | |
+ | * Blow aluminum oxide off part | ||
+ | * Use ShopVac | ||
+ | * Dispose of excess sharps | ||
+ | * Unplug camera, close air valve, turn off FlashCut CNC, turn off CrytalMark DV1 | ||
====Maintenance==== | ====Maintenance==== | ||
- | * Bed should be cleaned with IPA between prints | + | * Vacuum area before leaving. |
- | * Print heads and silicone head protector should be cleaned with IPA using a brush as needed | + | |
- | * Print cores should be swapped or purged after clog or to change print line width. | + | |
====Additional Information==== | ====Additional Information==== | ||
- | **Cura Model Settings** | + | You can record |
- | - //Move//: Allows you to move your model across the plane in the x-, y-, and z- direction | + | |
- | - // | + | |
- | - // | + | |
- | - //Mirror//: Allows you to mirror your model. | + | |
- | - //Per Model Settings//: Allows you to change print settings for each model. This allows you to have multiple prints on the same build plate while still using different print settings for each model. | + | |
- | - //Support Blocker//: Allows you to prevent support from being generated in certain areas. | + | |
- | - //Print selected model with Extruder 1//: Select which model to print with Extruder 1. This is generally build material. | + | |
- | - //Print selected model with Extruder 2//: Select which model to print with Extruder 2. This is generally support material. | + | |
- | {{: | + | |
- | + | ||
- | **Cura Print Settings** | + | |
- | - // | + | |
- | - // | + | |
- | - // | + | |
====Troubleshooting==== | ====Troubleshooting==== | ||
- | **Critical Printer Problems** | + | If the Crystalmark |
- | * Material is not extruding or under extruding | + | contact workshop staff to refill tool. |
- | * Ensure printing temperature is correct | + | |
- | * Material could be too moist and needs to be dehydrated in PrintDry chamber overnight | + | |
- | * Solution to - error message of “one material seems to be empty” | + | |
- | * Whenever installing/ | + | |
- | * Print core could be clogged - try using another print core and inform a staff member of clogged print core | + | |
- | * For staff - instructions for print core purge | + | |
- | * Ultimaker’s purge wizard does not work too well, what follows is a better custom recipe: | + | |
- | * Set clogged print core temperature to 230C | + | |
- | * Remove filament & filament tube from print head (use pliers to push down the tube collar fitting & pull out the tube at the same time) | + | |
- | * Insert clear purge rod into the print core through the hole that filament would usually go, and push down using pliers until it can no longer be pushed down or until clear material exits the nozzle | + | |
- | * IF clear purge rod cannot be pushed down further | + | |
- | * Reduce print core temperature to 130C then pull OUT purge rod | + | |
- | * Repeat above all of the above instructions (heat, push in rod, cool, pull out rod) until clear material can be seen exiting the nozzle | + | |
- | * IF/WHEN clear material can be seen exiting the nozzle, print core purging has been completed | + | |
- | * Reinstall filament tube & filament and proceed with print job | + | |
- | * Extruded material is not sticking to the print bed | + | |
- | * Clean bed with IPA and spray a thin layer of hairspray prior to printing | + | |
- | * Support material not extruding in the correct x-y position during dual material mode (PVA overlapping build material when it is not supposed to) | + | |
- | * X-Y offset needs to be calibrated - inform a staff member | + | |
- | * Error message of “there is a problem with the active leveling sensor” | + | |
- | * Ensure there is no debris between glass bed and aluminum plate | + | |
- | * Print bed needs to be manually leveled - inform a staff member | + | |
- | * Large clump/ball of material surrounding nozzle | + | |
- | * Stop print and inform a staff member | + | |
- | + | ||
- | **Print Quality Problems** | + | |
- | * Edges/ | + | |
- | * Adjust print orientation to reduce bottom layer surface area | + | |
- | * Clean bed with IPA then spray thin layer of hairspray prior to printing | + | |
- | * Decrease fan speed of bottom layers (custom settings) | + | |
- | * Bottom layer of print is wider than the rest of the print (aka elephant foot) | + | |
- | * Decrease bed temperature | + | |
- | * Brim is hard to remove from part | + | |
- | * Increase brim distance (custom settings) by 0.1-0.2mm | + | |
- | * Decrease bed temperature | + | |
- | * Overhangs are droopy | + | |
- | * Increase fan speed, decrease print temperature, | + | |
- | * Tiny holes on surface of print, part appears flimsy - print core is under extruding | + | |
- | * Use freshly dried filament | + | |
- | * Ensure print temperature is correct | + | |
- | + | ||
- | ====== F270 Printer ====== | + | |
- | + | ||
- | + | ||
- | ====Training Checklist: | + | |
- | *Components Overview: thermoplastics, | + | |
- | *Safety: NaOH bath | + | |
- | *Job Setup | + | |
- | *At the computer: GrabCAD, print parameters, record in FBS | + | |
- | *At the printer: build tray | + | |
- | *Part Removal Cleaning | + | |
- | *Tray removal, Sodium hydroxide solution cleaning process | + | |
- | *Rates | + | |
- | *ABS, Support, hourly charge | + | |
- | + | ||
- | ====Overview: | + | |
- | * This training provides an introduction to using and operating the Stratasys F270: | + | |
- | * File Types | + | |
- | * Software | + | |
- | * GrabCad Print | + | |
- | * Printer Use | + | |
- | * Post processing | + | |
- | * Prints with ABS | + | |
- | * Work by extruding thermoplastic filament onto build platform-Build the part layer by layer. | + | |
- | * Remember to enter job information into the 3D print job log! | + | |
- | + | ||
- | ====Safety==== | + | |
- | * As with any automated machinery make sure that your body is clear of the moving parts to avoid injury. | + | |
- | * The support removal tank is filled with heated caustic chemicals that dissolve the support material. An apron, Gloves, and a face shield must be worn when inserting and removing parts or basket from tank. | + | |
- | + | ||
- | ====Job Setup==== | + | |
- | *At the Computer: | + | |
- | -Load your STL file into GrabCAD on the computer adjacent to the printer | + | |
- | - Set Print Parameters: | + | |
- | - Position the part on the build tray in a way that is conducive to 3D printing (flat side down, minimize overhangs etc..) | + | |
- | - Select appropriate layer or slice height (the more slices the higher the print resolution but the longer it takes to print) | + | |
- | - The printer will print a raft before printing the model. Make sure first layer is set to support material or removal will be incredibly difficult. | + | |
- | - Send job to F270 over Ethernet | + | |
- | {{: | + | |
- | + | ||
- | **GrabCad Print overall Model Settings** | + | |
- | * //Overall view//: When you upload your print, this shows your overall model. | + | |
- | * //Analysis Mode//: This shows any errors detected in your print. To repair these errors, hit " | + | |
- | * //Slice Preview//: This setting allows you to inspect each layer of your print. You can choose which material to display. You can also add a Z-pause between layers, which allows you toswap material colors mid-print or add an insert. | + | |
- | + | ||
- | + | ||
- | {{: | + | |
- | {{: | + | |
- | + | ||
- | **GrabCad Print Model Settings** | + | |
- | *//Model Info//: Allows you to select individual components of your print and adjust the units (mm, cm, etc.) of your print. | + | |
- | *//Tray Settings//: Adjust build and support material, slice height. In this setting, it is **critical** to ensure that the first layer is support material, NOT build material. | + | |
- | *//Model Settings//: Adjust infill, body thickness, infill angle. | + | |
- | *//Support Settings//: Further adjust support style. | + | |
- | *// | + | |
- | *// | + | |
- | *//Scale//: Allows you to scale your model. | + | |
- | *// | + | |
- | + | ||
- | Make sure to record the material used and print time in FBS along with the other job information requested. | + | |
- | - **At the printer: | + | |
- | - Make sure that there is enough room on a CLEAN build tray for your part, and that the build tray is secured in the printer with the locking arm horizontal. Build trays may be used until the entire build area has been printed on, but printed areas should ideally | + | |
- | - Start the job at the printer | + | |
- | + | ||
- | **Post-Processing** | + | |
- | * Remove and flex the build tray to break the parts loose from their support | + | |
- | * Use a spatula to clean the build tray for the next job | + | |
- | * Don gloves, face shield, and lab coat | + | |
- | * Carefully, slowly and without splashing cleaning solution open the support removal tank lid, remove and open the tank | + | |
- | * Place large parts directly in the tank, small parts may be put in the SS box and placed into the main basket. | + | |
- | * Carefully, slowly and without splashing lower the basket back into the tank and close the lid. | + | |
- | * Set timer for 6 hours setting the temperature | + | |
- | * After cleaning time has elapsed follow the instructions above for opening and removing parts. | + | |
- | * Rinse part in warm water | + | |
- | + | ||
- | ---- | + | |
- | + | ||
- | ====Rates==== | + | |
- | F270: | + | |
- | + | ||
- | {| | + | |
- | |- | + | |
- | ! Material || $/Spool || cu in/Spool || $/cu in || $/cc | + | |
- | |- | + | |
- | PLA || 79 || 60 || 1.31 ||.08 | + | |
- | |- | + | |
- | ABS || 164 || 60 || 2.73 || .17 | + | |
- | |- | + | |
- | Sup || 228 || 60 || 3.79 || .23 | + | |
- | |} | + | |
- | + | ||
- | F270 hourly charge: $1/hr to pay for head replacement | + | |
- | + | ||
- | Ultimaker: ABS: .12/gram | + | |
- | + | ||
- | ----- | + | |
- | + | ||
- | ----- | + | |
crystalmarksop.1689786715.txt.gz · Last modified: 2023/07/19 17:11 by colin