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--- ultimaker_sop [2022/08/03 23:46] – wei
+++ ultimaker_sop [2022/08/27 00:23] (current) – removed haley
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-======Ultimaker Training SOP======
-Last edited: Wei (08/03/22) \\
-Tool Lead: Jason Wei\\
-Contact: jwei@ucsb.edu
-====Training Checklist:====
-  * Components Overview: thermoplastics, extruder, print head, print cores, build plate
-  * Safety: hot printheads & bed, moving components
-  * 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)
-  * Part Removal Cleaning
-    * Ultimaker: scraper, cold water rinse, warm bath support removal process
-====Safety Concerns====
-  * Both print heads and bed are heated during operation. Do not attempt to clean, remove, or adjust without allowing for adequate cool down time.
-  * Keep hands clear of printer during operation. Pause print before clearing or adjusting print.
- ====Common Mistakes====
-  *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 (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
- ====Safe Operating Procedures Review====
-  - Launch Cura version 5 (dark blue icon)
-  - Select printer and material(s) (ensure material is under 'Ultimaker' material section) on top selection bar {{:print_settings.png?600|}}
-  - Select File -> Open Files -> Open desired project (.STL file type)
-  - Using task bar on the left hand side, position model as desired
-  - Under print settings, reset all print settings to default by -> going to custom tab -> open Profile drop down menu -> select desired slice height -> open Profile drop down menu again -> select “Discard current changes” (if greyed out and not selectable, then the settings are already default)
-  - 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 .ufp 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/duplicate print settings profile (do not change default print setting profiles). Adjusting settings may lead to more (OR LESS) successful prints. Contact Workshop Wizard responsible for Ultimaker if print fails or knowledge of advanced settings is desired.
-====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====
-**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) \\
-====Maintenance====
-  * Bed should be cleaned with IPA between prints
-  * 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.
-====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 {{tools:ultimaker:gougemark.jpg}}
-    * 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 {{tools:ultimaker:printcorecleaning.jpg}}
-  * **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) {{tools:ultimaker:warping.jpg}}
-    * 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) {{tools:ultimaker:elephantfoot.jpg}}
-    * 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