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FELIXrobotics Felix 1.0 Instruction Manual

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Instruction manual
Felix 1.0 revision E, 3d printer-kit
Copyright Information
This document contains proprietary information that is protected by copyright. No part of this document may be photocopied, reproduced, or translated
to another language without the prior written consent of FELIXrobotics.
FelixRobotics
Hoogstraat 421H
5654NE Eindhoven
Netherlands
Copyright © 2012 FELIXrobotics.
info@felixprinters.com
www.felixprinters.com
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  • Page 1 Felix 1.0 revision E, 3d printer-kit Copyright Information This document contains proprietary information that is protected by copyright. No part of this document may be photocopied, reproduced, or translated to another language without the prior written consent of FELIXrobotics. FelixRobotics Hoogstraat 421H...

  • Page 2: Table Of Contents

    Table of contents Contents Table of contents ..............................................2 Introduction ............................................. 4 Required toolset ............................................. 4 Required skills ............................................4 Module 1: Frame (time: 10-30 minutes) ................................... 5 Module 2: Z-axis (time: 45-90 min.) ....................................9 Module 4: Hot-End (time: 20-45 mins) ........................Error! Bookmark not defined. Module 3: The Extruder (time: 30-90 min.) ..................................
  • Page 3 Calibration of table (5-15 mins)....................................42 It’s time for printing! (15- 30mins) .................................... 53 FAQ ..............................................55 BOM Felix 1.0 Revision D ......................................58 info@felixprinters.com www.felixprinters.com Page 3 of 65 ...

  • Page 4: Introduction

    Introduction First of all thank you for your purchase of the Felix 1.0 printer. To get your Felix printer up and running as fast and painless as possible please follow this manual. When things are unclear or if you have any remarks or tips, please contact us at info@felixprinters.com.

  • Page 5: Module 1: Frame (Time: 10-30 Minutes)

    Module 1: Frame (time: 10-30 minutes) Required for this module Tools Allen key set Level reference surface Level Parts Bag with description ‘frame module’. Aluminum beams. Overview of frame module The goal of this module is to create the frame on the right. Try to make everything as perpendicular as possible to each other. Let surfaces align as good as possible.
  • Page 6 sticking the hex-key through the holes. Do not fix it too tight because fine-tuning/leveling is needed later on. Take beam 4 and 1. They must be connected as oriented in the above picture. Slide one of the two beams number 2 onto beam 1. Watch the orientation of the drilled hole.
  • Page 7 Take beam 2 again and screw the frame connector on it’s far end. Then slid it on beam 3 as indicated on the picture. Next try to slide it also on beam 4. Thighten the screws, again not too tight. Now it is time for fine-tuning.
  • Page 8 Topview of frame Get the protective caps and mount them carefully with a hammer When all the beams are aligned and leveled, it is time to firmly tighten the frame connectors. Put the damping foots underneath the frame near the edge The handle should be mounted in the final stages of assembly.

  • Page 9: Module 2: Z-Axis (Time: 45-90 Min.)

    Module 2: Z-axis (time: 45-90 min.) Note: Most holes are designed to minimize the need for any post processing, like filing and drilling. Sometimes, however the bolts will not fit and it therefore needs to be drilled out slightly. Required drill sizes can be 3, 4 mm.
  • Page 10 Put the provided double sided tape underneath the opto-sensors and Mount the z-axis motor. IMPORTANT: the cables must be oriented mount them onto the printed part. Mount them with the small bronze according to the picture. screws. NOTE: Don’t screw it too tight, because that will deform the opto-sensor.
  • Page 11 The z-spindle mount should also touch the rail. Use a small washer and an M4x16 bolt The bottom of the motor should be aligned with the bottom of the frame. Mount the z-motor bracket with a small washer and an M4x12 bolt.
  • Page 12 Mount the big part onto the z-axis carrier with small washers and m4x12 bolts. Tip: put the bolts in place with the supplied tweezers. Slide the big z-axis carrier part onto the smaller z-axis carrier part as indicated in the picture above. To further connect the two z-axis carrier parts, turn the frame upside down.
  • Page 13 Also do the same with the m4 self-locking nuts. When approximately in place, try to keep the nut into place with your finger. Then with the other hand tighten the bolt with an allen key. When the thread of the bolt has catched the nut, then use the 7mm wrench to fix the nut.
  • Page 14 Pre-assemble the z-axis limit switch vane. Use a ring and M4x16 bolt for attachment to the frame. DO NOT mount it to the frame yet, because it is a delicate part it should be mounted in the final stages of assembly, Place the rod with the coupling in place.
  • Page 15 Screw the coupling on the spindle at the bottom end. Don’t forget to use a curved washer. Fix the coupling by holding it and turning the m8 bolt against it. Don’t fix it very tightly. The curved washer is to compensate for an uneven surface of the m8 nut.

  • Page 16: Module 3: The Extruder (Time: 30-90 Min.)

    Module 3: The Extruder (time: 30-90 min.) Collect the following tools Allen key set Large file BOM Extruder Part description Amount Extru_base_v7 Extru_base_pt2_v4 Extru_base_pt3 Extru_arm_v2 Extru_belt_clamp_v3 Extru_airduct_v2 motor nema 17 Fan 40x40x10mm small bearing extruder_insert_piece Get the extruder arm. Mount an M4x20 bolt. From left to right: M4x20 bolt, small washer, extruder arm, small washer, small bearing, self- locking M4 nut.
  • Page 17 Take the extru airduct and make the surface flat with a file. Careful, because it’s a delicate part. File a flat side to the motor and mount the bronze piece onto the motor. The distance of the motor_face to the bottom of the insert_piece should be approx.
  • Page 18 Mount the fans including one airduct. For the fan with airduct use M4x25 bolts including one small washer. For the other fan, use M4x20 bolts. Use small washers. Before combining all the extruder parts, even the surfaces as shown in the pictures.
  • Page 19 Put the parts together by using a m4x40 bolt shown in the picture. From left to right the encircled parts are: M4x40 bolt, medium washer, plastic part, medium washer, plastic part, medium washer, plastic part, small washer, m4 self prevailing nut. Watch orientation Connect the 2 sub-assemblies to complete the hot-end.
  • Page 20 To put tension on the extruder arm, mount the m4x30 bolt shown above. It seems short, but it is the correct length. Use 2 normal m4 nuts, 4 large washers and 3 crinkled washers. When you have it in place screw the 2 bolts up to put very little to no tension on the arm.

  • Page 21: Module 3: The X-Axis (Time: 30-60 Min.)

    Module 3: The X-axis (time: 30-60 min.) Note: Don’t waste any belt. There is only one long belt in the kit, which must be divided in such a way that it is usable for the x and y-axis. The top of theplastic part should touch the top aluminum beam.
  • Page 22 Push the extruder onto the x-axis slider. This can go with some resistance. But no need for drilling any hole out. Then fix it with m4x20 bolts and medium washers. Mount the motor to the x-axis motor bracket with the m3 countersunk bolts.
  • Page 23 x-axis belt mount It’s now time to mount the parts onto the frame. Before doing this cut the belt at one point and guide the end over the bearing as indicated above. (The part displayed in the picture above is from an older revision, but instruction are similar.) Put the t-slot nuts to mount the x-axis belt mount.
  • Page 24 Increase the belt tension by turning the bolt and moving the clamp away from the extruder base. When the belt is tightened normally by hand, the distance between clamp and base should be about 2mm after tensioning. This needs further fine tuning later. You have now finished the x-axis! Finally guide it through the belt-clamp.

  • Page 25: Module 5: Table (Time: 1-2 Hours)

    Module 5: Table (time: 1-2 hours) Important notes: Work carefully; this will benefit the print quality. Make sure that you don’t warp the surface of the table by exerting too much force /weight on the table BOM table Part description Amount table_2mm Resistor 4.7 Ohm - heated bed...
  • Page 26 - Glue the thermistor head approx. in the middle of the bed with heat resistant silicone kit or other heat resistant type of glue. - After glue-ing put some kapton tape on the wires to make sure the thermistor stays in place. - Let it dry.

  • Page 27: Module 6: Y-Axis (Time: 10-30 Min.)

    Module 6: Y-axis (time: 10-30 min.) Required tools for this module Allen key set. BOM y-axis Amount Part description y-stage bracket pt1_v5 y-stage bracket pt2_v4 y-stage bracket pt4_v3 Igus GmbH_NS-01-40 - rail Igus GmbH_NW-02- cart 20x10_profile t_slot_nut_5 Mount the small y-stage bracket pt4_v3 onto the y-stage bracket pt2_v4. Use a m4x25 bolt and a m4 nut.
  • Page 28 Get the small aluminum beam, first put the plastic cap on it, next to the M4 washers and 5 curved rings in total. See the illustration above. drilled hole. This can be done with a hammer. Now place the y-axis onto the table. When it doesn’t directly fit, there is no need to file any parts.
  • Page 29 Push the belt inside the bracket. Let the belt make contact with as much teeth of the bracket as possible. Also push it as far as possible, use a small allen key for that. If you have misplaced the belt or you want to remove it, on top of the bracket is a small hole which can be used to push out the belt with a small allen key.
  • Page 30 Next step is to tension the belt by turning the tensioning bolt. See picture above. The belt should be tensioned when the distance between the parts is approx. 1 to 2 mm. Check if you applied enough tension by pushing the belt as displayed above.

  • Page 31: Module 7: Electronics (Time: 2-4 Hrs.)

    10 Module 7: Electronics (time: 2-4 hrs.) The goal of this module is to install all electric wires and to neatly put them away in the frame. The required tools for this module are: Soldering iron Solder Flux Allen key 7mm wrench To make the printer work properly the schematics below must be matched.

  • Page 32: Mount The Powersupply

    Mount the power supply to the frame Label all cables Place as much cables as possible to the electronics board. Connect the y-axis table wires to the board. Connect the opto sensors Connect the motor wires Connect the rest of the wires Clean it up and place the wires into the frame and cable spiral.

  • Page 33: Connect All Possible Wires To Electronics Board

    It is very usefull to label all the cables, especially when you want remove a cable in the future for whatever reason. A easy way of labeling is to fold a piece of tape around near the connectors, and write something on it with a permanent marker. The three wired cables are for the opto sensors, the 4 wired cables are for the motors and the 2 wired cables are for the heated bed and hot-end temperature sensors (these are already mounted onto...

  • Page 34: Connect The Y-Axis Table Wires To The Board

    To prevent the power supply from being damaged, place some tape on the grill. Solder residu particles can easily fall in and cause a short. From the big ATX connector, cut 2 yellow and 2 black wires near the connector. (It does not matter which of the black or yellow wire you take.) You need this length to be able to reach the ramps case.

  • Page 35: Connect The Opto Sensors

    Make sure the loop is intermitted at the top part of the z-axis carrier. Mount it there with a cable tie. Then make the second loop from the z- axis carrier to the vertical beam. The second loop should go into the vertical beam at approx.

  • Page 36: Connect The Motor Wires

    10.5 Connect the motor wires The wires of the opto sensor should look like this on the z-axis carriage. Like this on the opto switch of the x-axis. Easiest is to start with the x-axis motor: From both ends remove excessive pieces of cable, IMPORTANT: do not throw away the cut off pieces of cable because it has to be used for later.

  • Page 37: Connect The Rest Of The Wires

    do not make a knot and then solder. This will prevent the 10.6.1 Wires for the hot-end. heatshrinks to go over the open piece of wire. The supplied hot-end contains all the wiring. The pre-crimped wire need To nicely seal the open wires, heat the heatshrink with a heat elongation in order for it to reach the ramps electronics.
  • Page 38 Get the heat sinks and put the self-adhesive conductive tape on it. Place the heat sinks on the square chip on the stepper drivers. Try to make the loops look nice by putting it in the cable spiral. Finally manipulate the bundled cable to let it through the opening. The cables must be pushed flat because the lid of the box must be placed on Join the cables near the power supply in an as neat as possible way.
  • Page 39 Cut of a piece of frame-strip to hide the cables that run through the frame. Finally the front view of the printer should look like this. Congratulations you are done with the electronics part and it is time for some finishing touches. info@felixprinters.com www.felixprinters.com Page 39 of 65...

  • Page 40: Finishing Touch (Time: 30-45 Min.)

    11 Finishing touches (time: 30-45 min.) Check all the bolts if they are tightened correctly. Check if all the axes can move freely, without cables being jammed. Put a little bit of oil or grease on the z-spindle, to make it run smoothly. Preferably a thicker kind of grease or oil, we use motor-oil. When you have a printer with a shining through color, the opto-sensors of the axes might not work.
  • Page 41 Prepare the heated bed. In this step the goal is to put a layer of tape on the surface of the heated Put strokes of the supplied tape on the heated bed. Try to do this with as bed. This layer makes sure the extruded plastic will correctly stick on the little bubbles and overlap of the strokes as possible.

  • Page 42: Calibration Of Table (5-15 Mins)

    12 Calibration of table (5-15 mins) For a successful print it is important that the table is properly calibrated, which means it should be level. The table can be leveled by turning the 3 M4 nuts underneath the heated bed. !!The calibration is done by moving the axes by hand!! Steps: Calibrate the table in y-direction.

  • Page 43: Making Printer Ready For Operation.(30 - 60 Mins)

    13 Making printer ready for operation. (30 – 60 mins) The software used to control the printer is open source. It is available for different platforms. This manual currently only covers the WINDOWS version of the print software. For other platforms, guides should be available on the internet. The software installation is split up in two steps.
  • Page 44 Select the correct platform: Tools -> Board-> Arduino Mega(ATmega1280) Select the correct Serial Port which you’ve noted earlier Tools -> Serial Port -> COM… Extract the downloaded FelixPrinter firmware to some folder. Marlin.INO Open this folder through the Arduino interface and click on the file.
  • Page 45 A new window will pop-up, with all the source firmware files. All the settings for the FelixPrinter to work correctly are configured. Feel free to browse around the files to get a better understanding of how it all works. It is time to upload. You are done with the firmware upload.
  • Page 46 iii. Click “advanced system settings” Click “Environment variables” Scroll on the lower part of the window till you see “Path” Click once on the line and then click “Edit …” Add the directory name of Python, don’t forget to put “;” in front of the name. vii.
  • Page 47 13.2 Printer software – Repetier-Host This software controls the printer. Also your CAD design files can be calculated and printed out by this program. 1. Download latest version of Repetier-Host from www.felixprinters.com 2. Extract the zip file. The following files/directories should appear. Choose the setup….exe file to install Repetier-host. Select the two directories and copy them into the installation directory of repetier-host 3.
  • Page 48 Match all the settings from the tabs. The com13 in the pictures is probably different for your situation. The com port is obtained in previous steps of the manual. info@felixprinters.com www.felixprinters.com Page 48 of 65 ...
  • Page 49 The software is now configured for printing. Now it is time to configure the slicer. This is the part which slices a CAD file and prepares it for printing. Go to Slicer and press setup. Match all the fields in the picture below and afterwards press OK. Press the Configure button The slicing settings must come up.
  • Page 50 Now it is time to slice our first object. Press the Add STL file. Then navigate to the installation folder of repetierhost and choose the _40x10.STL file from the subfolder displayed in the picture below. Slice with SFACT Slice this file and prepare it to print. Press the button When the program is done after slicing the interface should look like this: info@felixprinters.com...
  • Page 51 10. After slicing 13.3 Calibrate the Z-direction/ Connect to printer To obtain good quality prints it is essential that the heated bed is level and that the distance between the hot-end and the bed is close enough. The leveling is done prior to the software installation. So now it is time to calibrate the z-axis height with the z-axis limit switch vane. Make sure if you have a shining through color printed parts for the printer to apply the tape, tipexx to the limit switch vanes.
  • Page 52 Now it is time to calibrate the z-height.: Plug in the power cable. When doing the following steps, hold your hands on the usb connector. Plug it out if something goes wrong. Make sure the fan in front of the hot-end and the fan in the electronics case is turning. Make sure the bed is 1 cm from the hot-end.

  • Page 53: It's Time For Printing! (15- 30Mins)

    14 It’s time for printing! (15- 30mins) After all the hard work of the assembly and setting up the machine it is time to get some reward by means of your first successful print. Before pressing the “Print” button make sure of the following In the manual control window do the following.
  • Page 54 If the print looks like the picture above than congratulations your printer is completed!! IMPORTANT info: To keep the hot-end running as long as possible, let the filament run through a dust collector like a small piece of sponge. The filament picks quite a lot of dust due to static charge or dirt from the factory.
  • Page 55 15 Quest to high quality printing After experimenting a little with the printer, you probably want to get the most out of your printer. This chapter addresses some categories to increase print quality. 15.1 Thermodynamics Filament printing temperature is an important parameter. There is usually one optimal temperature to print at, this is different for each material type and even for different colors of the same material.
  • Page 56 Belts/Pulley’s Usually when perimeters ofexperiencing bad print quality, this can mean the followingMake sure the pulley’s are tightened. 1: Pulley’s are not tightened enough 2: Belt tension is not high enough. Hot-end Check that the hot-end is fixed in the extruder carriage. If not, the prints will come out ugly. 15.3 Software.
  • Page 57 16 FAQ Q: Sometimes the extruded filament looks ugly or has a varying diameter: A: Not homogenous extruded filament can be caused by the following: Check the filament quality. Bad quality filament can have a varying diameter from 1.95 to 1.4mm instead of a continuous 1.75mm. There is not enough tension on the extruder arm.

  • Page 58: Bom Felix 1.0 Revision D

    17 BOM Felix 1.0 Revision D Bolts and screws Amount ISO 4029 - M3 x 6-N - Set screw ISO 10642 - M3 x 8 --- 8N - Countersunk ISO 4762 M4 x 6 --- 6N ISO 4762 M4 x 12 --- 12N...

  • Page 59: Info@Felixprinters.com

    Printed Parts x-stage-motor-bracket_v5 x-axis belt mount_v4 y-stage bracket pt1_v5 y-stage bracket pt2_v4 y-stage bracket pt4_v3 z-spindelmount bottom - v3 z_axis_carrier_pt1_v3 z_axis_carrier_pt2_v5 z-axis-motor-bracket_v8 z-axis-limitswitch_vane_v4 Extru_base_v7 Extru_base_pt2_v4 info@felixprinters.com www.felixprinters.com Page 59 of 65 ...

  • Page 60: Info@Felixprinters.com

    Extru_base_pt3 Extru_belt_clamp_v3 Extru_arm_v2 Extru_airduct_v2 powersupply_bracket_pt5 powersupply_bracket_pt4 ramps_case_pt1_v2 ramps_case_pt2_v2 ramps_support info@felixprinters.com www.felixprinters.com Page 60 of 65 ...

  • Page 61: Info@Felixprinters.com

    Electronics Heater Cartidge incl 2m wires (pre-assembled in hot-end) Thermistor incl 2m wires (1 is pre-assembled in hot-end) RAMPS + arduino + steppers fully assembled Fan 40x40x10mm mini-ATX-seasonic, powersupply Power Cable NL(optional) Power Cable USA(optional) Power Cable Australian(optional) Power Cable British(optional) optosensor motor nema 17 Resistor 4.7 Ohm - heated bed...

  • Page 62: Info@Felixprinters.com

    Heatshrinks small 15 cm Piece of 2 thread wire 2m, for heatbed and hot-end Mechanics Igus GmbH_NS-01-40 - rail Igus GmbH_NW-02- cart Igus GmbH_NS-01-80 - rail Igus GmbH_NW-02-80 - cart pulley_motor_HTD Toothbelt 1.5m z-spindle bearing-8x22x7 bearing 5x12x6 extruder_insert_piece y-axis mid-table support 20x10_profile t-slot nut mini info@felixprinters.com www.felixprinters.com...

  • Page 63: Info@Felixprinters.com

    Frame 40x40x400 profile, incl 2xM8 40x40x400 profile, incl 1xM8, 1xD7 40x40x400 profile, incl 3xD7 80x40x440 incl work 40x40 protective caps 80x40 protective caps frame connector set handle incl protective cap hex sockethead bolt M8x16 buttonhead t-slot nut - 8 ST M8 t-slot nut - 8 ST M4 dampning feet strip for putting away cable pieces of 40 cm...

  • Page 64: Info@Felixprinters.com

    info@felixprinters.com www.felixprinters.com Page 64 of 65 ...
  • Page 65 Fabricated parts Hot_End_base_3mm Hot_End_peek_isolation_3_v2 hot_end_heated_nozzle_3 table_2mm Z-axis coupling_v11 Others tweezers tape for heated bed cable ties, set of 100 cable spiral 1.25m 2m cable piece of selfadhesive tape 10cm Piece of filament to start 5m info@felixprinters.com www.felixprinters.com Page 65 of 65 ...

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