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Installation & User Manual Bowden & varioDrive Original document Version 2020- 5.0...
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! Please read and understand the contents of this installation and user manual carefully ! Failure to read the manual may lead to personal injury, inferior results or damage to the BlackBelt 3D Printer. Always make sure that anyone who uses the Blackbelt knows and understand the contents of the manual and makes the most out of Blackbelt 3D Printer.
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1.3.1 Explanation of pictograms and symbols ....................10 1.3.2 Definition of users........................... 11 Transportation ..............................11 Introduction ............................... 14 Description of the BlackBelt 3D print platform....................15 2.1.1 Versions explained ..........................15 2.1.2 Bowden ..............................15 2.1.3 varioDrive ..............................15 2.1.4...
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Auto support in BlackBelt Cura with custom support blocker ................ 47 Using custom support ............................. 48 Customer service and support ........................55 Maintenance .............................. 53 Preventive maintenance ..........................55 Heated bed modification ..........................59 Calibration Y axis ............................. 56 Belt adhesion maintenance ..........................58 Spare parts ..............................
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Menu structure ............................. 102 BlackBelt PCB ..............................104 7.3.1 BlackBelt PCB v1.4 ..........................104 7.3.2 BlackBelt PCB v1.4 varioDrive ....................... 105 7.3.3 BlackBelt PCB v1.3 ..........................106 Possible failure mode ............................ 107 Disposing the machine or machine parts...................... 108 EG-declaration of compliance ......................... 12...
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A copy can be acquired through e-mail (info@blackbelt-3d.com) or download a copy on our website (www.blackbelt-3d.com) Do not use of the machine for any other purposes then intended by BlackBelt 3D BV. Not doing so can lead to serious damage to the machine or the machine-operator and its surroundings.
Completely switch of the main power switch and remove the connector from the wall socket. 11. If a part or sub-assembly of the Blackbelt 3D Printer has been damaged or is not functioning properly, please cease all activities or print jobs immediately. Only resume activities if the part has been repaired or replaced by a spare part.
In case of eventual damage caused by transportation, please report this damage immediately to your shipping agent or transporter and to Blackbelt 3D BV at all times. Take all necessary steps to prevent further damage to the machine.
Bremweg 7 5951 DK Belfeld Netherlands Declares that: Machine: BLACKBELT 3D-Printer Type: BLACKBELT 3D-Printer Desktop version complies with Machinery directive 2006/42/EG and complies to the provisions of the EMC-directive 2014/30/EG complies with harmonized European standards: Harmonised Harmonised Description Description European standard...
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We can separate them into two big groups: Flexibles (< 95 A) and Rigids (> 95 A). These terms are no standard and other suppliers might use different values. For the BlackBelt 3D printer platform we have developed two print systems that are dedicated to print optimal for one of the two groups.
2.1.4 Machine overview Number: Machine part: BLACKBELT 3D Printer (assembled) Conveyor belt (Z Axis) cold segment Angle Adjusting knob Conveyor belt (Z Axis) heated segment Cooling fan X Axis Y Axis (2x) Printhead assembly SD Card Slot Display Menu jog wheel...
2.1.5 Control panel & electrical cabinet Control panel / front side: Filament Insert lever SD Card slot Display Menu jog button Filament entrance USB port entrance Electrical cabinet backside: X motor connector (red) Y motor connector (green) Z motor connector (blue) Power main Fuse Main Switch...
7. 3x Printhead varioDrive specific 8. 1x varioDrive In order to operate the BLACKBELT 3D Printer, you’ll also need a computer (using Windows or Mac/iOS operating system) 3.3 Surroundings/Environment Set-up the printer on a stable table in a dry and clean room with a temperature between 15-35°C.
The connector with the blue indicator connects with the contact labeled “Z Motor”. The bigger connector without an indicator connects with the contact labeled “Heatbed”. The main power connector connects with the supplied power adapter to the wall socket. BLACKBELT 3D Control cabinet Printer...
3.4.4 Installation of the printhead [BOWDEN] Ensure the machine is switched “Off”. Ensure the machine is setup secure on a robust table and can be accessed from all sides. Contact PTFE Tube entry Spiral cable entry Contact control cabinet Cooling fan Printhead screws Cooling fan assembly...
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Bigger objects with less details can easily be printed with a bigger nozzle. Just changing the nozzle size will decrease printing time by a factor two if you double the size. Follow these instructions to change the nozzle size. 1. Make sure the material is removed according the steps in chapter 3.5.1 (Scenario 1: steps 1 + 2). 2.
3.4.5 Installation of the printhead [varioDrive] Ensure the machine is switched “Off”. Ensure the machine is setup secure on a robust table and can be accessed from all sides. Contact motor PTFE Tube entry Spiral cable entry cable Printhead screws Contact control cabinet Heater cable...
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1. Unbox the printhead assembly. On request other nozzle diameters are available in 0.25, 0.4, 0.6, 0.8 and 1.0mm Nozzle Diameter. The smaller nozzle diameter you choose the more detailed prints will result. However, small nozzle diameters will also increase printing time for a big object. 2.
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Bigger objects with less details can easily be printed with a bigger nozzle. Just changing the nozzle size will decrease printing time by a factor two if you double the size. Follow these instructions to change the nozzle size. 9. Make sure the material is removed according the steps in chapter 3.5.3 (Scenario 1: steps 1 + 2). 10.
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16. Release the lever and the nozzle together with the cooling unit. Don’t unscrew the rest. [7-8] 17. Installing the new nozzle please make double shore the two rings align properly before securing the lever back in position. WATCH THE POSITIONING UNDER THE BOLT [9-10] 18.
If a machine part has been damaged or is not functioning in the prescribed way, the machine operation must be stopped immediately and can only be resumed if the damaged part has been replaced or repaired. Please inform or consult Blackbelt 3D BV if the machine is not functioning properly. 3.5.1 Loading filament The Bowden and varioDrive system have a slightly different approach to material change.
3.5.2 Material change [BOWDEN] Please assure that the 3D Printer is fully assembled and wired correctly and that the printhead has been installed. Scenario 1: NOT during a print job and when the heater is cold. 1. Preheat the nozzle with the presets: Push the button →...
3.5.3 Material change [varioDRIVE] Please assure that the 3D Printer is fully assembled and wired correctly and that the printhead has been installed. Scenario 1: NOT during a print job and when the heater is cold. 1. Preheat the nozzle with the presets: Push the button →...
3.5.4 Explanation Menu 3D Printer When starting the BlackBelt 3D Printer, the following start screen will appear. [5] Target [1] Target temperature temperature heated bed printhead [2] Temperature [6] Temperature printhead heated bed [3] Position coordinates [7] Print progress [4] Speed...
3.5.5 Starting up a Print Assure that all previous steps have been executed completely and correctly. Hot Surface! Burn hazard when touching the hot surface. Entrapment hazard Danger / moving parts. 1. Insert the SD Card with the G-code into SD the slot (8) 2.
3.5.6 Stop the print In this chapter we will explain the most common manual ways to stop the printer. 3.5.6.1 Stop the print using the menu Push the jog button. Turn the button to the left and select “Stop Print” . Push the button again to stop printing immediately.
“BLACKBELT Cura” Select your operating system (Windows, Linux or OSX) to download the latest version of BLACKBELT Cura. 2. DoubleClick on the .exe file and follow the steps in the installation wizard. 3. Open “BLACKBELT Cura”, if this does not start automatically.
In order to generate the machine code (G-code) the following requirements are necessary: A Mac or PC equipped with a SD card reader. The BLACKBELT Cura software needs to be installed onto the hard drive as described in chapter 3.6...
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Printhead, using “Nozzle diameter” – we advise to use a 0.4 or 0.6mm printhead, to obtain detailed results Material, using “Material:” – we advise “BLACKBELT nGen” to be used for your first prints. 7. Move the model into the desired position: Select the model, click on “Rotate”...
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View: Machinecode Model position Solid View / Layer view Color indication Line types Preview Slider (2x) Estimated Print time Save machine code to SC Card Start point / first line of the machinecode 9. Have a look at the G-code / machine code and evaluate your model. You can see the nozzle movements (track) the print nozzle will be following, to build the product.
3.6.2 Saving a project If you are happy with the settings and you want to keep these for later, you can save the entire project in Cura as a *.curaproject.3mf file. This can also be convenient when you want to continue a later time or share your work with others.
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Otherwise the 3D object(s) will be loaded without settings. 5. BLACKBELT Cura shows an overview of the printer, profile and material that is saved to this project. It will also overwrite the visibility settings. If you agree to overwrite the current models and settings press “open” and continue with the project.
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If a new product is being printed, there is no previous layer. This means that the first layer needs to start onto the conveyor belt. Not every geometry is equally suited to be printed on the BLACKBELT 3D Printer. The model below is a cross section of a plane which does not start onto the composite belt: If the model starts above the belt, it is necessary to apply a support or starting geometry to the part, that can be modelled in using CAD software.
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Because of these facts, the design of the part needs to be considered carefully. While designing products for the BlackBelt 3D Printer it is important to consider the direction the product will be printed. The cross section below can easily be printed from left to right.
4.2 Using auto generated support 1. Make sure the Auto generate support is on and check if the Support Pattern and Support Density is according specifications. 2. Check all the other parameters like material settings and Prepare your GCODE for printing. If auto slicing is on this will happen automatically.
4.3 Manual support in BlackBelt Cura 1. Open the Marketplace and install Custom Supports 2. Selected the model you want to support and click on the new icon in the menu on the left. 3. Click ON the model near the location and a cube 5x5x5 appears, place a s many as you need. By deselecting the option in the menu to the left you will lock the amount of support blocks.
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Keep in mind that support is generated full height and in between the object all the way to the platform if it touches the object. 4. After deselecting the adding custom support tool you can move and scale the support. For a better control deselect uniform calling and work with individual scales.
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6. Make sure the Auto generate support is off and check if the Support Pattern and Support Density is according specifications. 7. Check all the other parameters like material settings and Prepare your GCODE for printing. If auto slicing is on this will happen automatically.
4.4 Auto support in BlackBelt Cura with custom support blocker Follow steps 1-5 from the previous chapter 4.3, the only difference is that you position the blocks where no support is needed. You can also do this with custom generated support in CAD after you import them and merged the files.
4.5 Using custom support The custom support mentioned in the previous chapter can be designed in your CAD program [1-2]. Make sure that the support geometry is a separate volume body that has no offset to the product geometry. It is possible to overlap the geometries.
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4. Open a sketch and project the BODY on the surface. Most CAD software inlcude a function to project the “shadow” of the object onto a surface. This is the easiest solution. You can also get this result by projecting single lines and curves.
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7. If the your satisfied with the offset and the erea is active for extrusion. Use the EXTRUSION UP TO BODY to make a NEW BODY. This feature takes some getting used to since it sometimes not preforms as expected. This can be due to under cutting or if an surface is equal to the extrusion surface.
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10. Save both files to a folder on your system on which BlackBelt Cura is installed. Make sure both files share a common origin. If the models do not align in the next steps this is the most common issue.
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4.6 Support for long profiles For printing longer profiles the only support structure needed. This part you can later remove or cut off. Especially flex materials are best to just print 10 mm extra in front and in the back and remove these parts later. 1.
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Our technical and support department will answer all your questions about repair and maintenance of your machine and spare parts. Team BLACKBELT 3D is happy to advise you regarding your purchase, use of the machine and setting up the products, as well as applying the correct design guidelines. Please contact us at support@blackbelt-3d.com.
5.3 Calibration Y axis You’ll need a 5mm and 3mm Hexagon key and a sheet of paper 5. Set the gantry to 45° and mount a printhead. 6. Take a piece of paper, put it on the conveyor belt and place the printhead onto it: 7.
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Set screw 12. Adjust the set screw to level the gantry - clockwise if the printhead is now at the same side, or counterclockwise, if the printhead is now at the other side. [5-6] 13. Tighten the 3 screws again 14.
5.4 Belt adhesion maintenance To increase the adhesion between the 3D printed part and the conveyor belt, the belt surface can be cleaned by detergent. Especially when 3D Lac or any other adhesion agency is used we strongly advice to clean the belt at least every month.
5.5 Heated bed modification When printing long parts or parts that need additional heating for a longer period, the machine can be adjusted for a longer hot zone. This is often used when printing with filament that requires a heated bed above 80 degrees Celsius and is bogger then 100 x 100 mm in length and height.
Only original spare parts and machine parts of BlackBelt 3D BV can be used in the machine. All consumer and spare parts can be found in the web shop of Blackbelt-3d.com or by direct inquiries at sales@blackbelt-3d.com. When sending inquiries always remark the number of parts and specifications.
5.7 Changing the belt Please make sure all the material is removed from the printer. The material removal steps are explained in chapter 3.5. 1. Turn off the machine and disconnect the controller box [1-3] 2. Remove the printhead, please make sure all the cables are removed [4-6] Version 2020-5.0_ENG...
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45° position 3. Remove the controller box, make sure that there is enough space to the right of the machine 4. Set the machine to 45° 5. Remove the 2 screws at the hinge – the gantry will now hold its position [9-10] 6.
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8. Take off the gantry and put it to the left besides the printer [13] 9. Set the base unit upright [14] 10. Loosen the rear roller with the rear 2 screws [14] 11. Unmount the rear roller while holding it with the other hand [15] 12.
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17. Turn the base unit back on its feet [24] f. Make sure the belt is between the guiders! In the latest models the guiders have been removed from the design. In that case make sure it is in the middle, with even space left and right. Follow instructions in Chapter 5.8 for the belt calibration before continuing this guide.
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18. Put the gantry back on the base unit and mount it in 45° position with the 2 angle adjusting knobs [25] 19. Mount the 2 screws at the hinge back again. [26] 20. After a belt-change you will need to calibrate the Y axis as explained in chapter 5.8. Version 2020-5.0_ENG...
5.8 Calibrate the belt In this procedure we need to touch the belt with the hands. Make sure that you have clean hands with no grease on them to keep the conveyor belt clean. Make sure that the conveyor belt is in between the limitations. [1-2] Check the tension of the belt.
5.9 Synchronize the Y-motors You’ll need a 1,5mm Hexagon key When you encounter misalignments during printing or small level shifts, a likely cause can be non-synchronized y-motors. Please follow these steps to make sure the Y motors are synchronized again. 1.
The USB cable supplied with the BlackBelt 3D printer. 1. First turn on the BlackBelt 3d controller by flipping the main switch and make sure it powers up. 2. Hook-up the machine to the MAC or PC using the USB cable. The USB port of the printer can be found in the front side of the controller console marked USB (figure 1+2).
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6. The upgrade menu should open where you choose “Automatically upgrade Firmware”. Wait for the process to complete and close all the windows until your back in the main program. Your 3D printer is now up to date with the newest version of the BlackBelt Firmware Blue symbol for...
5.11 Manual upgrade firmware [varioDRIVE] Follow steps 1-4 from the previous chapter 5.10 and continue with the following steps: 5. Now select the BlackBelt 3D printer varioDrive if this is not already the case and press “Upgrade Firmware” (figure 3).
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In order to correctly update the firmware, the following requirements are necessary: A Mac or PC equipped with an SD card reader. The newest version of BLACKBELT Cura software needs to be installed onto the hard drive as described in Installation manual chapter 3.6 http://www.blackbelt-3d.com/download-area...
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8. First turn on the BlackBelt 3d controller by flipping the main switch and make sure it powers up. 9. Hook-up the machine to the server box with the USB cable. The USB port of the printer can be found in the front side of the controller console marked USB (figures 1+2).
1. Move the clip over the webcam with the rubber dots towards the lip. [1-2] 2. Place the webcam on the inside of the frame with BlackBelt logo on it. Make sur the lip is on the outside. [3-4] 3.
6.1.2 Software setup To make sure the BlackBelt server runs optimal in your local network run the following steps to setup all the software. 1. Open your browser and surf to the IP-address that is shown on the LCD screen and a login screen will pop-up.
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The USB-cable to the printer is not connected (connect it) c. The printer itself is busy or in error state (finish the print or restart the printer). d. If it none of the above, contact support@blackbelt-3d.com for further assistance. Version 2020-5.0_ENG...
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5. If everything is ok and the printer is connected. You should see an Operational state and a temperature read out [ 7 ]. Version 2020-5.0_ENG...
Printing with the wrong physical setup can cause damage to the printer. 1. Prepare a file in BlackBelt Cura like your used to for SD-card printing. 2. Save the file to a known location on your device as GCODE.
Load Print Add to printqueue 6.1.4 Print queue The BlackBelt Server is equipped with a special Print Queue plugin developed to print 24/7. Especially for series production of custom objects this is a must use feature. Position or File print...
6.1.5 Timelapse Need to promote your work or check up on production flaws or failures the Timelapse is a great feature. The following modes are available: 1. Off: nothing happens 2. Timed: take a picture every set interval (standard every 10 seconds). For prints that take up a day or more we recommend 30 seconds interval.
6.1.6 Adding multiple users If your using the printer with multiple users and want to make use of different privileges, there is an option to add multiple users with different user levels. For this go to the settings menu [1 - wrench symbol] and go to the access control section.
6.1.7 Control Control window for manually controlling the printer. The webcam will install automatically and show up as image here. If the webcam is showing an image that is upside down or mirrored, you can change this in the settings menu [ 1 ]. Webcam image Fan control...
6.1.8 Webcam settings Sometimes the image of the webcam is upside down or mirror. Use the settings below to change the picture orientation. Version 2020-5.0_ENG...
6.1.10 Possible failure mode Problem Possible cause Action / solution Blackbelt server seems to be offline boot issues restart / reboot the server 2 times. This so far only occurs the first time on a new network IP address does not occur on the LCD false The Ip address is send once to the LCD display.
6.3 Run-out sensor For the Blackbelt we use a dedicated run-out sensor that can be retrofitted to all the older models as well as requested as a feature on purchase. Packing list run-out sensor Amount Description order number Run-out sensor...
6.4 Using the run-out sensor The run-out sensor is an optional gadget which allows you to chance the filament during the print. The run-out sensor detects when the printer is running out of filament and puts the print on pause. 5.
If you have purchased a varioDrive update kit and you want to retrofit this on your platform you can use the following guide. For questions and encountered problems contact us through our support channel support@blackbelt-3d.com. Packing list VD retrofit Amount...
6.5.2 Dismantling the Bowden drive 11. Set the gantry to the 45° position. 12. Unmount the print head before starting, make sure there is no filament in the printer left. 13. Open the electrical cabin by removing the entire cover. 14.
9. Check if there are no lose wires in the electrical cabinet and power the machine. 10. Install the new firmware manually (Marlin 1.1.9.1 BLACKBELT VarioDrive.ino.hex) 11. The printer should now be ready to use. Make use of the project files to get the latest settings for different materials.
6.6 BlackBelt support frame Packing list support frame Amount Description order number Frame pt1 Frame pt2 Printer mount use description M8 sliding nut M8 x 14 M10 x 60 5mm Allen Key BB-P0098 4mm Allen Key use description Wooden packing box...
6.6.1 Assembly guide 1. Mount one of the sides to the top frame. 2. Mount the second side and middle frame to the previous assembly 3. Put the entire frame up right with the feet level on the floor. Make sure the frame does not wobble and is level.
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4. Position the Printer on the frame make sure the rear feet are behind the mid- beam (orange in picture) and the front feet are in front of the frame. 5. Fix the supplied fixtures with screws delivered as set in the package. Version 2020-5.0_ENG...
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6. Position and mount the electrical cabinet and spoolholder onto the correct locations. Note: the printer is left out of this picture for visual purposes. 7. The result should look like this. Version 2020-5.0_ENG...
6.7 BlackBelt roller table Packing list roller table Amount Description order number Roller table pt1 Roller table pt2 use description M8 x 20 M8 sliding nut Top mount N10 5mm Allen Key BB-P0098 Wooden packing box BB-P0026 User manual use description...
6.7.1 Assembly guide 1. Mount the legs to the bottom of the rollerframe. 2. Flip the construction and the final assembly should look like this in combination with the support frame. Version 2020-5.0_ENG...
7.1 Materials The BlackBelt 3D printing platform is unique due to the carbon fiber print belt that is used as a print surface. Each print surface has its unique settings and material preferences that work well. For the Blackbelt 3D printing platform the following materials are tested and recommended.
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Due to the close relation with colorFabb we have a good collaboration program around testing general and new materials. The Blackbelt printing platform is not limited by these materials, but there is little widely spread information on the adhesion to carbon fiber belts. Also, material suppliers often do not have info on this printing surface.
Best way to keep track of all the different material settings is to make use of the Material library integrated in BlackBelt Cura. Use the following instructions to add custom materials to the library. To add new materials, go to the Manage Materials menu [1] under materials tab.
7.2 Menu structure By turning the jog button on the control cabinet, it is possible to change a setting or scroll through the menu structure. By pushing the jog button, is it possible to select a menu item or confirm the set value. Grey settings are only available for the varioDrive setup.
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Main Back to the previous screen Temperature “Temperature” menu Control Back to the previous screen Nozzle: Set temperature printhead Bed: Set temperature heated bed (belt) Fan Speed 1: Set fan speed (0= off, 255=full power) Fan Speed 2: Set fan speed rear fan (0= off, 255=full power) Autotemp: Function, to adapt the temperature of the printhead automatically to the print speed.
7.3 BlackBelt PCB In this chapter you find the connection schedules for the different versions of the BlackBelt 3D PCB’s that are on the market. We strongly advise to get in contact with us before changing any connectors or modifying wires inside the controller box.
7.3.2 BlackBelt PCB v1.4 varioDrive Print head Rear Fan Heat bed Fan + heater 1 Brown 1 Brown 1 Pink 2 Blue 2 White 2 Gray 3 Blue 4 Red Print head Fan 2 1 White 2 Brown Display Exp 2...
Possible cause Action / solution 3D printed part detaches from the belt Too fast belt wall Enable the feature “Belt Wall” In BLACKBELT Cura or belt and set it between 10 and 15 mm/s. Temperature too Slice the part and see the result in Layer View option “Feedrate”.
7.5 Disposing the machine or machine parts Please follow all prescriptions as described in this manual. In particular chapter 1.3 : Safety messages Carry out the following steps while disposing the machine: 1. Put the machine out of order and detach all electrical connections. 2.
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