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--- ultimaker_3_sop [2022/06/27 20:32] – wei
+++ ultimaker_3_sop [2022/08/27 00:18] (current) – haley
@@ Line 1: / Line 1: @@
-======Ultimaker Training SOP======
+====== FDM Training SOP======
-Last edited: Wei (06/27/22) \\
+Last edited: Haley Holcomb (08/26/22) \\
 Tool Lead: Jason Wei & Andrew Furst \\
 Contact: jwei@ucsb.edu & Andrewfurst@ucsb.edu
+====== Ultimaker Printers ======
 ====Training Checklist:====
@@ Line 9: / Line 11: @@
   *Job Setup
     *At the computer: CAD -> export .stl -> Cura (print parameters, support materials) -> export .gcode/.ufp -> USB stick -> plug into printer -> record in FBS
-    *At the printer: clean print bed (Ultimaker)
+    *At the printer: clean print bed
   *Part Removal Cleaning
-    *Ultimaker: scraper, plate removal, warm bath support removal process
+    *Scraper, cold water rinse, warm bath support removal process
   *Rates
@@ Line 21: / Line 23: @@
   *Inadequate part adhesion to the bed - can cause print failure or breakage of entire print head assembly
     *Can be prevented with proper bed cleaning, use of hairspray, bed adhesion print settings, and high enough printing temperature
-  *Not drying PVA dissolvable support material for at least 10 hours prior to print - can cause PVA to stop extruding during a print, resulting in print failure
+  *Not drying PVA (can apply to PLA as well) dissolvable support material for at least 10 hours prior to print - can cause PVA to stop extruding during a print, resulting in print failure
@@ Line 35: / Line 37: @@
      * 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 or .ufp file from Cura to a USB drive
+  - 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
@@ Line 46: / Line 48: @@
 ====Post Processing====
+  * Remove part from print bed using a scraper (if part is too hard to remove, remove print bed and rinse part under cold water for 20 seconds)
   * If support was constructed from ABS carefully break away with pliers
   * If support was constructed from PVA soak part in warm water for several hours to dissolve support structure
+====Part Removal and Cleaning====
+  * Remove part from print bed using a spatula or razor being careful not to cut yourself or scratch the build plate. Make sure no body part is in line with the tool should it slip or the part break free unexpectedly.
+  * If support was used, submerge print in warm water for several hours to dissolve PVA filament. (prints can warp if submerged in water for over 24 hours) \\
 ====Maintenance====
@@ Line 71: / Line 78: @@
   -   //Layer thickness, infill, support//: Allows you to adjust the thickness, infill, and support you wish to use. **Ensure that you enable adhesion**
+====Troubleshooting====
+**Critical Printer Problems**
+  * Material is not extruding or under extruding
+    * 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/reinstalling filament, ensure that there are **no deep bite/gouge marks on the filament**. This will cause extrusion failures
+    * 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/corners of part are warping (lifting off of the build plate, common for ABS prints)
+    * 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, and/or consider using support
+  * 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, extruder, print head, print cores, build plate
+  *Components Overview: thermoplastics, extruder, print head, print cores, build tray, material wells
-  *Safety: hot printheads, support removal tanks
+  *Safety: NaOH bath
   *Job Setup
-    *At the computer: appropriate software for each printer, print parameters, support materials, record in FBS
+    *At the computer: GrabCAD, print parameters, record in FBS
-    *At the printer: clean print bed (Ultimaker), clean build tray (F270)
+    *At the printer: build tray
   *Part Removal Cleaning
-    *Ultimaker: tray removal, warm bath support removal process
+    *Tray removal, Sodium hydroxide solution cleaning process
-    *F270: tray removal, Sodium hydroxide solution cleaning process
   *Rates
-    *Ultimaker: ABS
+    *ABS, Support, hourly charge
-    *F270: PLA, ABS, Support, hourly charge
 ====Overview:====
-  * This training provides an introduction to using and operating the FDM 3D printers including:
+  * This training provides an introduction to using and operating the Stratasys F270:
     * File Types
     * Software
-      * Cura
       * GrabCad Print
     * Printer Use
     * Post processing
-    * Printer Maintenance
+  * Prints with ABS
-      * Changing Print Heads
-      * Changing Fulfillment Type
-      * Cleaning
-  * The two FDM printers (Ultimaker and F270) are both set up to print with with ABS by default, Other materials are available upon request.
   * 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====
-  * The print heads can be very hot - do not touch them with bare hands unless positive they are cool.
   * As with any automated machinery make sure that your body is clear of the moving parts to avoid injury.
-  * The support removal tank for the F270 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.
+  * 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 the print software on the computer adjacent to the printer (Cura for Ultimaker, GrabCad Print for F270).
+    -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)
-    - For Ultimaker:
+      - 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.
-      - Select "generate support" if necessary
-      - Check appropriate filament and bed temperatures (should be set if using standard filament load out)
-      - Send job to Ultimaker using USB drive
-{{:modelsettings3.png?600|}}
-  - For F270:
-      - The F270 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
 {{:fdmf2701.png?600|}}
@@ Line 149: / Line 182: @@
 Make sure to record the material used and print time in FBS along with the other job information requested.
   - **At the printer:**
-    - Ultimaker:
-      - Make sure print bed is clean
-    - F270:
       - 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 not be reused.
     - Start the job at the printer
-====Part Removal and Cleaning====
+**Post-Processing**
-**Ultimaker**
-  * Remove part from print bed using a spatula or razor being careful not to cut yourself or scratch the build plate. Make sure no body part is in line with the tool should it slip or the part break free unexpectedly.
-  * If support was used, submerge print in warm water for several hours to dissolve PVA filament. (prints can warp if submerged in water for over 24 hours) \\
-**F270**
   * 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
@@ Line 173: / Line 199: @@
 ====Rates====
+F270:
-F270:
 {|
 |-
@@ Line 188: / Line 214: @@
 F270 hourly charge: $1/hr to pay for head replacement
-Ultimaker:
+Ultimaker: ABS: .12/gram
-ABS: .12/gram
 -----