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Filament Innovations BFP-ICARUS Series Operating Manual

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Last Revised on 4/25/19

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Summary of Contents for Filament Innovations BFP-ICARUS Series

  • Page 1 Last Revised on 4/25/19...

  • Page 2: Table Of Contents

    Table of Contents Quick Start Guide ................................3 Quick Fact Guide ................................4 ICARUS Print Out ................................5 Introduction .................................. 6 Unboxing ..................................7 Toolbox Contents ................................9 Component Locations ..............................10 Touchscreen Interface ..............................16 Initial Setup and Calibration ............................17 Leveling the Machine ..............................

  • Page 3: Quick Start Guide

    Quick Start Guide The following quick start guide allows you to check and monitor the progress of you unboxing your printer and getting ready for the first print. It is recommended to check each step off here to ensure everything is done in order and correctly.

  • Page 4: Quick Fact Guide

    Quick Fact Guide The following quick fact guide will give you a brief overview of your printer. Machine Size: ICARUS Size: 42x29x44 (inches) ICARUS-X Size: 42x29x56 (inches) Print Envelope: ICARUS Print Area: 475x410x610 (mm) ICARUS-X Print Area: 475x410x915 (mm) Mechanical: X and Y Motion: HiWin Linear Rails &...

  • Page 5: Icarus Print Out

    ICARUS Print Out Last Revised on 4/25/19...

  • Page 6: Introduction

    Introduction The BFP-ICARUS line of 3D Printers was built to fill a clear need in the 3D Printing sector: large-scale, affordable, and reliable 3D Printers. This 3D Printer combines the latest technology and hardware into one unit. By using this unit, you are supporting Built in America machines and helping to push innovation in numerous fields, such as medical research, education, and rapid prototyping, to name a new.

  • Page 7: Unboxing

    Unboxing The BFP-ICARUS line of 3D Printers ship in a wooden crate, weighing between 400-450lbs. The BFP-ICARUS has crate dimensions of 40”x48”x48” and the BFP-ICARUS-X has crate dimensions of 40”x48”x63”. Once the crate is delivered, two people can easily unbox the machine. You will need the following tools: ...
  • Page 8 Once inside the crate, you will find the 3D Printer and a wrench screwed to the bottom of it (shown below). This wrench is used to raise the rubber stabilizer feet so the wheels can make contact with the ground and the printer can be pushed around.

  • Page 9: Toolbox Contents

    You and a friend can now remove the printer from the crate by carefully rolling it off. The printer should still be in the shrink wrap at this time. Toolbox Contents We include a toolbox with the basic tools you will need to maintain your machine, located inside the 3D Printer.

  • Page 10: Component Locations

    Component Locations From this step here, the unit should be placed where you want the printer to operate. With the unit in place or close to being in place to where it will operate, remove all the shrink wrap from the machine. Before we go any farther, let’s take a few minutes to understand the various components of your ICARUS unit.
  • Page 11 BL-Touch Bed Leveling Sensor (in Yellow) X Motor Last Revised on 4/25/19...
  • Page 12 Y Motor Z Motor, Ballscrew, and Thrust Bearing (two assemblies on the bottom) Last Revised on 4/25/19...
  • Page 13 Electronics Case (Inside - Duet 2 Wifi, 24VDC Power Supply, Solid State Relay) Switch Panel – Top of Control Case Last Revised on 4/25/19...
  • Page 14 Filament Sensor and Cleaner Duet 2 Wifi Screen and 24VDC Power Gauge Last Revised on 4/25/19...
  • Page 15 Stabilizers and Casters (style of caster is subject to change) GECKO Print Plate (removable), Glass Bed, Bed Leveling Springs, Aluminum Bed Last Revised on 4/25/19...

  • Page 16: Touchscreen Interface

    Touchscreen Interface We use a 7” LCD Touchscreen from the team at Duet3D, the PanelDue 7i touchscreen. This screen is the most advanced touchscreen available for 3D Printers. It allows for the user to easily interact with the printer and custom macros can be written to communicate with the printer.

  • Page 17: Initial Setup And Calibration

    Dark Blue: Home command for each axis. The left icon is a Home All command to home all three axes. Note – the machine will not move any axis from the touchscreen MOVE command until the machine is fully homed. Use the Home All button to do this –...
  • Page 18 Caster/Stabilizer Feet Adjuster: Before Adjusting the Casters: Last Revised on 4/25/19...

  • Page 19: Removing Aluminum Print Bed Supports

    After Adjusting the Casters: All four sides of the printer should be within an acceptable leveling range by having the leveling bubble between the two lines. At this point, you can now cut and remove the two zip ties holding the X axis to the Y axis near the hotend. The X and Y axis are zip-tied together to prevent shipping damage.
  • Page 20 16mm Shaft Collar – Four Total: With the shaft collars loosened and dropped to the bottom, we need to level the aluminum bed. This is done by holding the bubble level underneath the aluminum bed with one hand, and using the other to manually turn a ballscrew (Z axis) to bring it in line.

  • Page 21: Powering The Unit On

    Powering the Unit On The ICARUS units run on 110VAC current, this is standard household electricity found in the USA. The addition of the 110VAC heated bed can draw up to 10 amps during initial heating. Please choose an outlet that does not have a high amperage draw to ensure no breakers pop.
  • Page 22 Switches: Description of the switches in order - front to back: Red Toggle Switch: Main unit power. Blue Toggle Switch: LED lighting (will only turn on if the 3D Printer is on via the red rocker switch). Emergency Stop Switch: Kills all power to the unit in the case of an emergency. If the button is pressed down, then emergency stop is engaged.
  • Page 23 At this point, the unit should be powered on by ensuring the blue switch on the Fused Power Switch is glowing and the red toggle switch is flipped. You will know when the unit is powered on because the touch screen will turn on and cooling fans will engage.

  • Page 24: Bed Height Adjustment And Automatic Leveling

    Keeping a level bed is critical for accurate 3D Printing. Every ICARUS unit comes equipped with mesh bed leveling to ensure a flat bed. While your bed leveling and Z-offset is set by the Filament Innovations staff, we need to once again check that no damage occurred during shipping.
  • Page 25 Step Two - Ensure the bed is still level that was done prior by using the included bubble level. If not, manually twist one of the ballscrews. Step Three – Use the Home All button to home the X, Y, and Z axes. The printer axes will now start to move.
  • Page 26 Step Four - Press the Macro button on the touchscreen, then “Bed Compensation” as shown below. Step Five - Finally, press Bed Tilt Compensation and the printer will probe the left center and right center of the bed. The printer will then auto-level itself by moving one Z axis motor.

  • Page 27: Understanding Automatic Bed Leveling And Baby Z Stepping

    Understanding Automatic Bed Leveling and Baby Z Stepping 3D Printing requires a very flat bed surface for large, successful prints. Because of this, we have included two forms of bed leveling for your machine. This section of the guide is to inform you of what these two bed leveling options do –...

  • Page 28: Bl-Touch

    the print bed to the nozzle, therefore decreasing the distance between the two. A positive Z-offset will lower the print from the nozzle, therefore increasing the distance between the two. BL-Touch The BL-Touch is arguably the best auto-bed leveling sensor in the world. This probe, in our real world testing, will probe within a 20 micron accuracy every time it is engaged.
  • Page 29 At some point in time, the BL-Touch will go into an error state by flashing extremely rapidly. As seen below, we have created macros to help you reset the probe. If your BL-Touch is in an error state (flashing extremely rapidly), you will go to this section in the Macro area of the touchscreen and press “Test Probe”...

  • Page 30: System Pre-Heating

    System Pre-Heating In order to preheat the entire system, we need to set the desired temperature for the hotend and heated bed individually. The hotend should be preheated to the desired printing temperature for the filament you are using. You only need to turn the heated bed on if you want to perform a full Mesh Bed Leveling Compensation or want to pre-heat the system for printing.
  • Page 31 Last Revised on 4/25/19...
  • Page 32 Step Three – Initiate the heating process by pressed the Heated Bed icon. The heated bed will now start to heat up. The same process is followed for pre-heating the hotend. Last Revised on 4/25/19...
  • Page 33 Alternatively, we also have Macros made for system preheating as well. We have pre-heating guidelines set for: ABS, ASA, Nylon, PETG, PLA, and TPU. Please note, for final printing, you should always print at the manufacturer’s suggested temperatures. Our pre-heating macros should be treated as guidelines for that polymer.

  • Page 34: Filament Loading

    Filament Loading Loading the filament in the ICARUS unit is fairly straight forward and simple. First, before we load any filament, we need to mount the spool holder on the left of the machine. The two bolts to mount it to the machine are screwed to the machine, on the top left.
  • Page 35 Filament Loaded in the Exterior PTFE Tube: Filament through the Sensor: Last Revised on 4/25/19...
  • Page 36 Extruder Prepped for Loading (note the black lever is towards the Teflon tube): There is a locking knob (orange circle) to the left of the tube, that will hold the lever open for loading – you need to press the knob towards the lever, when the lever is pulled to the left, for it to grab: Extruder Prepped for Printing (release the locking mechanism by pushing the lever to the left, it will go to the right when released, you are now loaded):...

  • Page 37: Lid/Chamber Exhaust Fan

    You can push filament through, with the lever open, until you see it coming out of the nozzle (assuming the hotend is heated to the correct temperature). When you see the filament coming out of the nozzle, you can release the lever. The filament is now loaded.

  • Page 38: Wifi Connectivity

    Wifi Connectivity Connecting the 3D Printer to the Wifi Network The Duet2 Wifi board comes with built in Wifi connectivity for 2.4ghz networks (it will not work on 5ghz networks). Official documentation for connecting to your printer to the internet can be found here: Official Wifi Documentation Because we set up and test each unit before we ship it - we already do all...

  • Page 39: Connecting The Wyze Webcam To The Wifi Network

    Step Two – Enter your wireless network’s name and password exactly as shown below by typing it into the LCD screen using the on-board keyboard feature. As shown below, be sure to enter your own network name where the FilamentInnovationsShop word is and your own password where the word 3dprinting is.
  • Page 40 included in the box and those found on the smartphone app. You can mount the camera inside the printer wherever you like via the double-sided taped, disc included in the Wyze box, but we recommended mounting it as shown below for a full view of the print bed (circled in yellow).

  • Page 41: Software Profiles And References

    Software Profiles and References The BPF-ICARUS line of 3D Printers can be used with any slicer, but we strongly recommend Cura or Simplify3D. There will be a MicroSD card inserted on the bottom right of the touchscreen for offline printing and it will include files for the printer.
  • Page 42 Start gCode (copy and paste it in) M561 ; clear any bed transform G28 ; home all G32 ; check bed tilt G29 S1 ; load prior mesh map Last Revised on 4/25/19...
  • Page 43 End gCode (copy and paste it in) M104 S0 ; extruder heater off M140 S0 ; heated bed heater off G91 ; relative positioning G1 E-1 F300 ;retract the filament a bit before lifting the nozzle to release some of the pressure G1 Z+0.5 E-5 X-20 Y-20 F9000 ;...
  • Page 44 Cura has a second tab for the nozzle diameter and filament diameter to be entered. There is no special gCode settings for the Extruder 1 tab.  Simplify3D o Under File - Import FFF Profile select the profile that is relevant to your machine and import it (ICARUS or ICARUS-X).

  • Page 45: Maintenance

    Maintenance This section will cover general maintenance of your printer to ensure it remains in great shape. Your ICARUS unit needs very little maintenance to keep it in optimal condition, but as with any machine, some maintenance is needed. Machine Cleaning and Oiling 3-IN-1 Oil should be applied in small amounts to the X linear rail, the two Y linear rails, four vertical smooth 16mm rods, and ballscrews once a week (or as needed).

  • Page 46: Gecko Plate Prep And Use

    General debris, such as filament pieces, should be cleaned from the machine weekly, as well as checking the belts and pulleys for any debris and removing them. GECKO Plate Prep and Use Your GECKO plate has a consumable skin coating that is good for roughly 300 prints before it needs to be replaced.

  • Page 47: Acrylic Cleaning

    Acrylic Cleaning The ICARUS machines look gorgeous cleaned up and you will want to use cleaners designated for acrylic to keep it clean. We recommend a microfiber towel and a product called Rolite. You can find Rolite on Amazon. NEVER USE RUBBING ALCOHOL OR WINDEX TO CLEAN THE ACRYLYC (OR ANYTHING WITH AMONIA IN IT).

  • Page 48: Maintenance Ports

    Maintenance Ports All ICARUS units come with two simple maintenance ports – the blue acrylic on the front drops down and the top lid opens up – this is shown below. Last Revised on 4/25/19...
  • Page 49 Below is a four picture tutorial on how to use the door handles you see on the ICARUS. To open a compartment, follow the instructions listed below. To close a compartment, simply do the reverse of the operation. Step One – Locate handle. Step Two –...
  • Page 50 Step Three – Turn handle – the clasp is now disengaged. Step Four – Open compartment. Last Revised on 4/25/19...

  • Page 51: Wiring

    Wiring Last Revised on 4/25/19...
  • Page 52 BFP-ICARUS Motherboard Wiring Diagram BFP-ICARUS Power Diagram Last Revised on 4/25/19...

  • Page 53: Helpful Links And Resources

    The 3D Printing community is like none other. There has been a tremendous amount of information released on 3D Printing over the years. Here are some helpful links and resources to help you be an expert.  Updates and Profile Revisions: Filament Innovations  Simplify3D Slicer: Simplify3D  Cura Slicer: Cura ...

  • Page 54: Frequently Asked Questions (Faq)

    Frequently Asked Questions (FAQ) Do BFP-ICARUS 3D Printers use proprietary filament? Absolutely not – you are free to use any 1.75mm filament. Because we are printing larger scale items, we do highly recommend you use quality filament to ensure the large prints finish. What size nozzle is stock? Unless otherwise requested, all units ship with a 0.6mm nozzle to balance speed and quality.
  • Page 55 It is very beneficial to have a hotend for each temperature range. Please note the cooling fan must be removed above 275C so the shroud does not melt! Why does the extruder show a negative C temperature at room temperature? The Dyze Designs thermistor is very powerful, but lacks the ability to read room temperatures accurately.

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